Ball Joint Repair S60 2001-2009

61: Front axle crossmember, control arm
S60 2001-2009 L.H.D
20/10/2015 Print
  61: Front axle crossmember, control arm  
Ball joint, replacing
Volvo special tools "may" be required for installing the ball joint on S60 models. Special tools are special order and call for price.
Special tools:
9512050
9512927
9997076
9997148
9992709
9995500
9995796
9995781
9997231
9997062
9997230
9995467

Note! The illustrations in this service information are used for different model years and/or models. Some variation may occur. However, the essential information in the illustrations is always correct.
Preparatory work
Note! Replace on both sides.
Remove the front wheels.
Removal
Removing the ball joint nut
Applies to vehicles with aluminum link arm

Remove the nut on the control arm. Use a Torx wrench as a counterhold.
Applies to vehicles with steel control arm

Remove nut.
Removing the ball joint in the control arm
Applies to vehicles with steel control arm

Install nut 9997231 on the ball joint with a clearance to the link arm of approx. 1.5 mm. Volvo special tools available for special order

Align puller 999 7062 with the link arm and nut 999 7231 .
Tighten the puller 999 7062 so that the ball joint releases from the link arm.
Applies to all

Caution! Do not pull the drive shaft as the axial pinions cannot support large loads.
Note! If the hook is positioned at point (2) there is a risk of damaging the rubber boot on the ball joint.
Press the control arm down using lever 999 7076 . Position the hook at (1).
Release the spring strut from the control arm.
Removing the ball joint screws

Remove the 2 x screws for the ball joint.
Removing the ball joint

Applies to vehicles with aluminum link arm
    Install:
  • the nut: 999 7148 on the ball joint
  • the sledgehammer: 999 2709 on the nut.
Applies to vehicles with steel control arm
Use nut 999 7230 and impact hammer 999 2709 .
Applies to all
Tap off the ball joint.
Cleaning the ball joint mounting
Warning! Always use protective goggles.
Clean the mating surfaces for the ball joint and seat. Use a rotating wire brush.
Lubricate the seat with wheel bearing grease, part number 1161689 (75 ml).
Installation
Note! For tightening torques, see: Tightening torque .
Installing the guide screws
The guide screws: 999 5781 have a wrench grip (see arrow) which is asymmetrically positioned.
Aluminum wheel spindle
Use the screw (1) with the greater distance from the wrench grip.
Steel wheel spindle
Use the screw (2) with the shortest distance from the wrench grip.
Installing the ball joint
Applies to vehicles with aluminum link arm

Caution! Leave the protective cap for the ball joint in position to prevent damaging the rubber boot.
Loosely install the new ball joint using the guide screws.
Applies to vehicles with steel control arm

Caution! Take care not to damage the ball joint boot.
Temporarily remove the protective cap from the ball joint.
Loosely install the new ball joint using the press tool 999 5781 .
Applies to all

Caution! Take care not to damage the ball joint boot.
Press the ball joint up towards the seat. Use press tool 999 5796 . Check that the ball joint is centered in the seat.
Knock in the ball joint. Use a copper mallet.
Remove the guide screws.

Tighten the ball joint. Use 2 x new screws. Tighten. See: Tightening torque .
Remove the protective cap.
Installing the control arm and ball joint

Caution! Do not pull the drive shaft as the axial pinions cannot support large loads.
Note! If the hook is positioned at point (2) there is a risk of damaging the rubber boot on the ball joint.
Press the control arm down using lever 999 7076 . Position the hook at (1).
Align the spring strut in the control arm.
Installing the ball joint nut
Applies to vehicles with aluminum link arm

Caution! The ball joint pinion must not rotate. Use: 951 2927 as a counterhold to prevent damaging the rubber boot
Note! Use 999 5500 as a torque wrench.
Note! A counterhold is not required when angle tightening if the joint has been tightened to 50 Nm. The friction between the ball joint and control arm is greater than between the nut and threads on the ball joint.
Install the 1 x nut.
Tighten according to step 1. See Tightening torque:Summary of tightening torques for specific components .
Use bevel protractor: 951 2050 .
Angle-tighten according to step 2. See Tightening torque:Summary of tightening torques for specific components .
Rust protect the thread outside the nut.
Applies to vehicles with steel control arm

Use socket 999 5467 as adapter for the torque wrench or a cap wrench adapter that is deigned for torque wrench.
Install the new nut and tighten acc. to Tightening torque .
Rust protect the thread outside the nut.

20/10/2015 Print