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6 days ago

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Volvo S40/V40 1995-2004 tie rod replacement procedure

johna posted 6 days ago

Ball joint tie rod, protective bellow or tie rod, replacing (procedure extracted from Volvo VIDA)

Special tools:
999 7019 (Steering deflection limiter)
999 7020 (Counterhold)
999 7021 (Steering deflection limiter)
999 5637 (puller)

Removal

Removing wheels

Note! The wheel must be removed before the tie rod can be removed.

Raise the car to a comfortable working height. Remove the wheel.

Removing the ball joint for the tie rod

Slacken off the locknut for the tie rod.

Remove the pin and the castle nut (if applicable), or the lock nut for the ball joint for the tie rod.

Use special tool 999 5637.

Warning! Tie the tool in place using the cord so that it cannot fall off and cause damage.

Press out the ball joint with the special tool.

Remove the ball joint from the tie rod (note the number of turns).

Removing the boot

Preparing the right-hand boot

Remove:
• the heat deflector plate from the cowl panel
• the screw from the heat deflector on the steering gear housing. Pull the heat deflector away from the steering gear housing
• the tie strap (2) for the boot on the side of the steering gear housing.

Removing the boot

Remove the ball joint from the tie rod. See Ball joint tie rod, protective bellow or tie rod, replacing: Removing the ball joint for the tie rod.

Remove:
• the locknut (1). Note the position of the lock nut
• the tie straps (2). (only on the right-hand side of the tie rod) Note! Cover the threads until the boot is reinstalled. Use masking tape.
• the boot for the tie rod.

Removing the tie rod

Preparing the right-hand tie rod

Remove:
• the support for the power steering pipe and hose
• the ball joint and the boot from the tie rod. See Ball joint tie rod, protective bellow or tie rod, replacing: Removing the ball joint for the tie rod and Ball joint tie rod, protective bellow or tie rod, replacing: Removing the boot.

Positioning the counterhold

Note! Ensure that all components are clean when carrying out this procedure. The seals in the steering gear are sensitive to scratches on the steering rack.

Clean the tool and the surfaces of the steering rack thoroughly.
Slide the steering rack approximately 10 cm outwards.

Remove the locking washer (if there is one).
Position the special connection plates 999 7021 in special tool 999 7020.
Position special tool 999 7020 as tightly as possible against the tie rod.
Tighten to a maximum of 25 Nm.

Caution! Slide special tool 999 7020 horizontally forwards against the steering rack.

Removing the tie rod

Position special tool 999 7019 over the tie rod on the ball joint.
Ensure that both tools positioned on the end are the same length.
Unscrew and remove the tie rod.
Remove the lock plate or the spacer.

Installation

Installing the tie rod

Clean the tie rod mounting.
Position the new lock plate (or spacer) with the flange against the steering rack. Align the plate with the connection ring for the steering rack.
Turn the tie rod ± 7 mm up on the steering rack. Secure the flange in the snap ring for the steering rack.
Finger tighten the tie rod.
Apply tape to the threads on the tie rod to prevent damage.
Secure the tie rod. Use special tool 999 7019. Tighten to 88 Nm.

Removing the counterhold

Remove the counterhold.

Secure the locking washer (at least 1) by tapping the lock plate (if lock plates are installed).
Clean the surfaces of the steering rack thoroughly after removing the tool.
Install the boot and the ball joint on the tie rod. See Ball joint tie rod, protective bellow or tie rod, replacing: Installing the boot and Ball joint tie rod, protective bellow or tie rod, replacing:Installing the ball joint on the tie rod.

Installing the boot

Check that the boot is undamaged.
Use a new boot if uncertain.
Tape the threads on the tie rod to protect the boot.

Install:
• grease, P/N 1161001-1, on the steering rack and on the inside of the boot
• the boot. Secure the boot using new tie straps (2) (only applies to the right-hand tie rod)
• the lock nut (1) in its original position (count the number of turns).

The ball joint on the tie rod. See: Installing the ball joint for the tie rod.
If the boots are on the right-hand side.

Install:
• the clamp (2) on the steering gear housing
• *the heat deflector on the steering gear housing
• the mounting screw for the heat deflector
• the heat shield at the cowl panel.

When replacing the right-hand tie rod

Install the support so that it is secure.
Tighten to 25 Nm.
Install both brackets on the support.
Tighten to: M6 screw 10 Nm, M8 screw 15 Nm.

Installing the ball joint on the tie rod

(Count the number of turns)

Install:
• the ball joint for the tie rod in the wheel spindle
• the castle nut/lock nut. Tighten to 24 Nm.

If applicable, install the split pin.
Only tighten the castle nut further if required to insert the split pin.

Check the toe-in. See Wheel alignment, checking/adjusting.

Installing the front wheel (right-hand tie rod)

Install the front wheel.

Parts

Tie rod end (21/21a)
Phase 1 (< 2000), chassis numbers < 599999
Both sides: Volvo 30875012, Febest 0421-457, Lemforder 15560 01
Phase 2 (2001-2003), chassis numbers 600000-999999
(2003+), chassis numbers > 1
Left: Volvo 274225, Lemforder 27612 01
Right: Volvo 274226, Lemforder 27613 01

Steering rack end (9/9a)
Phase 1 (< 2000), chassis numbers < 599999
Both sides: Volvo 3345797, Febest 0422-DA, Lemforder 25487 01
Phase 2 (2001-2003), chassis numbers 600000-999999
(2003+), chassis numbers > 1
Both sides Volvo 274224, Lemforder 38922 01

Steering boot (19/16)
Volvo 3345796, Febest MRKB-DA, Lemforder 30220 01

Alternative tools and procedures

Some people have reported that some standard long inner tie rod removal tools do not fit the S/V40 and have had success with the Autozone 25296 tool. There is a similar tool available inexpensively on eBay, Aliexpress, Temu, etc.

In place of the counterhold tool and inner tie rod removal procedure mentioned above, The Haynes manual procedure says to wrap a layer of insulating tape around the end of the steering rack and gripping it with an adjustable spanner. Then while unscrewing the inner tie rod using a pair of grips, hold the rack with the spanner to prevent strain on the rack. Use the same procedure when fitting the new inner tie rod.

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