VOLVO 940 1982 Service Repair Manual

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Automatic transmission ZF
70019401960 Specifications
Section
4 Power Transmission
·~~7i6~3:9:91 SERI.AL NO. ~
1043010153 MODEL NO. ~
4HP-22 Q -~ IF Gelriebe GmbH ~ Saarbrilcken
Type and designation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ZF 4HP 22
Reduction ratios, 1 st gear .................................... .
2nd gear ................................... .
3rd gear .................... ................ .
4th gear (overdrive) .......................... .
Reverse
... ................................. .
Torque converter, type
....................................... .
reduction ratio
............................................ .
size
................. ........................... .
Lubricant
.......... ......................................... .
Oil fill quantity ............. ................................. .
Part numb er, stall speed
E ngine ,/ Volvo P/N °
B23E, B230E 1208375 1208502
1208391 1208662
B230ET 1208376 1208503
1208480 1208609
B
230 F Europe 1987-1208518 1208601 1208680
B 230 F Others 1208301 1208501
(not estates 1987)
B230FB 1208686
B 230 FT Europe 1987-88 1208517 1208610
D24 1208407 1208594
1208505
D24 T Europe 1208317 1208506 1208664
1208389 1208595
D 24 T USNCanada 1208365 1208507 1208665
Austria 1987-
1208390 1208596
D24
TIC 1208397 1208663
0) ZF and Volvo part numbers stamped on type designation plate. Last three digits of Volvo number also stamped on rear of gearbox .
024,024 TITle
2.73:1
1.56 :1
1:1
0.73:1
2.09:1
024
218K
Other e ngin es
2.48:1
1.48:1 x converter-
1:1 ratio
0.73:1
2.09:1
Other engin es
195K
1-approx 2.57 1-approx 2.3
260
mm
ATF oil type Dexron II D'
7.5 litres incl oil cooler and tubes (2.5 litres = 2.6 US
qts approx in torque converter)
Stall speed1
rls (rpm )
36.0 (2150)
33.3-41 .0 (2000-2450) 2
35.0 (2100)
35.0 (2100)
33.0 (2000)
33.3-41.0
(2000-2 45W
36.0 (2150)
31.7-39.0 (1900-2350)2
30.0-33.3 (1 800-200W
31.7-40.8 (1900-2450)2
I) At sea level. Stall speed drops 2 rls (120 rpm) for each 1000 ·metre (3300 feet) increase in altitude . 2) Start-stall.
149
I
III til' 'IIt til ' ,lit
lit
,lit til ,III

I
I
70019401960 Specifications
Section
4 Power Transmiss ion
Thrott le cab le setting
Distance between adjusting sleeve and cable stop
at
idling ......................... ......................... .
kick-down .
.. , ............. ........................... . , .. .
0.25-1 .0 mm 51 +1 .6 mm - 0.6
Line pressure (at id le )
(Measure at plug indicated by arrow) MPa psi
(85-108)
(156-199) Idling , D .................................. 0.6-0.76
Idling , R .............................. .... 1.1-1.4
Line pressure at stall speed, ZF
Engine Position 0
MPa psi
B23E 0
.83-1 .03 118-147
B230E 0 .83-1 .03 118-147
B230F/FB 0 .95-1.15
135-164
B230ET 0.95-1.15 135-164
024 0.86-1.06 122-151
D24T 0.81-1 .01 115-144
Austria 1987-
USA/Canada
Othe rs 0 .99-1 .10 141-156
D24TIC 0 .96-1 .06 137-236
Gear shift speeds km/h (mph)
Engine Ratio
B23E 3.73 :1
B230E 3 .73:1
B23 0F 3.91 :1
USA/Canada
B230F 3 .91 :1
Eur ope 1987-
B23 0FB 3.91 :1
B23 0ET 3.91 :1
3 .
73:1
B230FT 3.73 :1
Europe 1987-
024 3.91 :1
D24T 3.91 :1
Austria 1987-
USA/Canada
Oth ers 3 .73:1
D24TI C 3.73 :1
Throttle valve opening %
* Kick-down ** Late type.
150
1-2 2-3
62 (39) 107 (67)
62 (39)
107 (67)
59 (37) 102 (64)
59 (37) 102 (64)
64
(40) 107 (67)
59 (37) 102 (64)
62 (69)
107 (67)
62 (39)
107 (67)
46 (29)
83 (52)
46 (29)
83 (52)
48
(30) 87 (54)
48
(30) 87 (54)
100 * 100*
Position R
MPa psi
1.51-1 .72 215-245
1.51-1.72 215-245
1.61-1 .
81 229--257
1.61-1 .
81 229--257
1 .57-1.76
223-250
1.48-1 .67 211-238
1 .
61- 1.82 229--259
1 .5
7-1.76 223-250
3-4 4-3 3-2
128 (80) 43 (27) 98 (61)
128
(80) 43 (27) 98 (61)
122
(76) 41 (26) 93 (58)
122 (76) 4
1 (26) 93 (58)
131 (82) 38 (24) 102 (64)
122 (76)
41 (26) 93
(58)
128
(80) 43 (27) 98 (61)
128
(80) 43 (27) 98 (61)
98 (61) 34 (21) 79 (49)
98 (61) 34 (21) 79 (49)
103 (64) 35 (22) 82 (51)
103 (64) 35 (22) 82 (51)
85
0 100
*
2-1
52 (33)
52 (33)
50 (31)
50 (31)
54 (34)
50 (31)
52 (33)
52 (33)
39 (24)
39 (24)
41 (26)
41 (26)
100 *
0.001-0.040 in
2 +0.063 in - 0.024
Mechanical lock-up
E ngages" D isengages"
96 (60) 94 (59)
85 (53) 83 (52)
78 (49) 76 (48)
85 (53) 83 (52)
85 (53) 83 (52)
92 (58) 90 (56)
97 (61) 95 (59)
97 (60) 95 (59)
76
(48) 74 (46)
73 (46) 71 (44)
87
(54) 85 (53)
87
(54) 85 (53)

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70019401960 Specifications
Section
4 Power Transmission
Tig ht enin g to rqu es
Nm ftlb
Drive plate-torque converter M 8 ................ .............. . 17-27 12-20
M10x 1.25 ......... .............. . 41-50 30-36
Torque converter -engine, M 10 .............................. . 35--50 25--36
M12 ........................ ...... . 55--90 40-65
Valve body -transmission gearcase ....................... .... . 7-9 5--6.5
Plate above parking detent ............ ............ ........... . 9--11 6.5--8 .0
Rear case -gearcase .............................. ......... . 20-26 14-19
Strainer - valve body -gearcase ................ ............ . . 7- 9
5--6.5
Governor -balance -pawl .......... ......................... . 9--11 6.5--8.0
Oil pump -separator plate .................. ................ . . 9--11 6.5--8 .0
B 4 cylinder -gearcase ...................................... . 9--11 6.5--8 .0
Plug -separator plate, M 14 .................................. . 34-46 25--33
M20 ....... ................ ...... ..... . 43- 57
31-41
Torque converter casing -separator plate -gearcase ........... . 40-52 29-38
Oil pan -gearcase .......................................... . 7-9 5--6.5
Drive plate -output shaft .................................... . 85--115 61-83
Blind plug, oil pan .................... ................. ...... . 13-17 9--12
Oil filler tube -oil pan ....................................... . 85--115 61-83
Group 45 Propeller shaft
/'
Tightening torque, flange bolts,
steel
joint M 8 ....................... ...... ..............•..
M10 ......................... .. ................ .
rubber joint ...................................... ......... . *Use service kit 9122130-9, socket 9995381 -2
ikd@
1 39 137
30 Nm (22 ft Ibs) + angle-tighten 60°*
50 Nm (36 ft Ibs)
80 Nm (58 ft Ibs)
Group 46 Rear axle
Rear axle , 740 , 760* , 780 -1987, 940 , 965
Reduction ratio ...................................... ....... . 3 .31:1, 3.54:1 , 3.73:1, 3 .91:1, 4 .10 :1 Axial throw, crown wheel ..................................... . Max 0.08 mm Max . 0.003 in Backlash ... ................................................ . 0 .12-0.18 mm 0 .004-0.007 in Preload torque, pinion bearings, new .......................... . 2.5--3.5 Nm 1.8-2.5 Ibs used ...... ... ................ . 1.8-3.4 Nm 1.3-2.5 Ibs
Preload, differential bearings ................................. . 0 .05--0 .08 mm 0.0019-0 .0032 in Clearance , speedometer sensor -pulse wheel .... .. ........... . 0 .5--1.2 mm 0 .020-0.047 in Radial runout outer diameter, pulse wheel ........ : .. : ......... . Max . 0.3 mm Max . 0.0118 in Lubricant ....... . ........................................... .
See page 9
*1988--only 5- doors.
151
III 1 .... 1 III ·111 III ·111 III ·111

70019401960 Specifications
Section
4 Power Transmission
Tightening torqu es
Pinion drive flange, pinion with spacer .......... ........ ....... .
pinion with compression
sleeve ' ............ .
Differential bearing caps .............................. ...... . .
Crown
wheel " .. ............................ .......... ...... .
Wheel nuts ...... ............................... .. .......... .
Lock nut -speedometer sensor .
............................. .
• Do not exceed specified torque .. Use new bolts.
I Final drive 760 /780 4-door 1988-, 960
Reduction ratio ................................... .......... .
Axial throw , crown wheel ..................................... .
Backlash ............... .................................... .
Pinion bearing
preload , new .................................. .
old ........ .. ..... .................... .
Differential bearing, preload .................................. .
Clearance , speedometer' -impulse wheel ....... ............... .
Radial throw , outer diameter, impulse wheel ....... ............. .
Lubricant.
..... ............................................. .
T ightening torque s
='.. Coupling flange -pinion (nut) ................................ .
Crown
wheel -differential housing bolt + 60 deg . angle-tightening.
Wheel nuts .. ............................. .................. .
Impulse sender -rear casing (bolt) ............................ .
Rear casing -
final drive (bolt) ................................ .
Side bracket -final drive (bolt) ............................... .
Lock washer -adjustment nut
(bolt) ........................... .
Balance weight -final drive (bolt) ............................. .
Oil drain plug ............................................... .
Oil filler plug ................................................ .
Drive shaft
bolts (+900 angle tightening) ....................... .
Drive shaft nuts,
(+600 angle tightening) ............... ........ .
152
Nm ttlb
200-250 147-185
180-280 130-207
45-60 33-44
90-110 66-81
85 63
25-40 18-29
3.54:1, 3.73:1, 3.91:1
Max 0.08 mm (0.0032 in)
0.1-0. 16 mm (0.04--0 .006 in)
1.2-2.8 Nm (0.87 -2.0 ft Ib)
1.0-2.5 Nm (0.72-1 .8 ft Ib)
1 + 1 notches on each side
0.35-0.75 mm (0.014--0.030 in)
Max.
0.2 mm (0. 008 in)
See page 9
Nm
180-280
35
85
8-12
20-28
40-56
40-56
20-28
27-40
27-40
30
140
ftlb
(133-207)
(26)
(63)
(6-9)
(14--20)
(29-40)
(29-40)
(14--20)
(20-29)
(20-29)
(22)
(103)

70019401960 Specifications
Section
5 Brakes
Section 5 Brakes
fJy ~~
132426
B rake fluid
Grade................................... .... ... ............ DOT 4
Fron t wheel brakes
(
Brake disc, outer diameter, .. .................... .. .... mm (in)
thickness new
............................ . mm (in)
change at
........ ........... .............. mm (in)
Alt I Alt" Alt III Alt IV
! non -
ve ntil ated
ve ntilat ed ventilated
ventil ated
('Jumbo')
I
280 (11.0) 287 (11.3) 262 (10.3) 280 (11.0)
14 (0.55)
22 (0.87)
22 (0.87) 26 (1.02)
11.0 (0.43) 20.0 (0.79) 20 .0 (0. 79) 23.0 (0.91)
run-out -1987 ... ....... .. ................. mm (in)
max 0.08 (0.003)
1988-.................. ........... mm (in)
Brake pad thickness, new .
............................ mm (in)
min
.... ............ ........... ... mm (in) max
0
.06 (0.0024)
I 11.5 (0.453)
('Jumbo' 12.0 (0.472)
3
(0. 12)
Rear wheel brakes
Sta ndard Multi -link
Brake disc, outer diameter ....... ...................... mm (in) 281 (11.06)
265 (11.04)
thickness, new ............................. mm (in)
change at
............... ........ mm (in)
runout .
...................... ............. mm (in)
Brake pad thickness , new .
..... ....... ............... . mm (in) 9
.6 (0.378)
10 (0.393)
I
min 8.4 (0.330) 8 (0.314)
max
0.10 (0.0039)
0.08 (0.003)
10
(0. 393)
8 (0.314)
min ............ .................. mm (in)
2 (0.078) 2 (0.078)
T ight enin g torque s
Nm ftlbs
Attaching , bolts , front brake calipers ........................... . 100 (74)
rear brake calipers ............................ .
58 (43)
caliper bracket ....................... ....... . .
48 (35)
front dust
shield .................... ... (approx .)
24 (18)
rear dust
shield ................ ....... (approx.)
brake
caliper, slide pin ................... ..... .
40 (29)
"I 34
(25) II Wheel nuts ................................................. .
85 (63) II II Attaching nuts, master cylinder ..... ................... (approx.) 30 (22) II II Bleeder screws, front ......................... ........ (approx .)
5 (4) II ·11 rear ...... .......... ................. (approx .)
4.5 (3.3) II
Brake pipe unions ...... .......... ............ ............... .
14 (10) Brake hoses to nipple ....................................... .
17 (12)
Nipple to caliper ......... ................................... .
17 (12)
153

70019401960 Specifications
Section
5 Brakes
Parking brake
123427
Brake drums, radial runout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max 0.15 mm
out of round . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max
0.2 mm
Full braking effect after adjusting at . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 notches
when checking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . max
11 notches
154 max
0.0059 in
max 0.0078 in
-r

(
70019401960 Specifications
Section
6 Suspension and steering
Section 6 Front end and steering
Group 60 Wheel alignment
(Empty vehicle)
Front wheel alignment
Caster ..................................................... 4.5-5.5°
Cambe r*
... ................................... ........ ..... -0.2 -+0.8 °
• Difference between left and right-hand locks must not exceed o.r.
Toe-in
All variant s*
Angle (2 (X) A-a 8-b C-c
18'±8' 3.2±1
.3 mm 2.3±1.2 mm 2 .1 ±0.9 mm
0 .12±0.05 in 0.0 .9±0.05 in 0.08±0.04 in .-
• In order to simplify workshop routines, the same values apply to all 740/940/960 models from 1982. Older values may still be
found in some manuals and are not incorrect, though now sup­planted by these newer values.
All measurements to be carried out on an empty vehicle. Dimensions are noted at hub height in the form of an angular
measurement a or as the difference in mm between the front and rear edges of the wheels at points A, B or C (the tire tread,
shoulder and wheel rim edge respective ly).
Ball joints
Max axial play with normally loaded front end, 3 mm
(0.12 in)
Max radial play, 0.5 mm (0.02 in).
Wheel alignment, rear wheels
(
Multi -link )
Negative Camber IfJl
'legall. umb .. 113' -1.0
;l
+
a +a ~ -0.
r;-~ -0.6
P--I I­
ii I-i . IT -'. ! . -.1-Un k arm angle (n)
-0
-0
.
Un k a~ angle (a)
-4 -'.-3 "';-2 1 +i +2 + +4 1-
-~~ u ~ 1"'--H---. 1-i-J:-L
_. f-L -\-;-_1_ i-'-1.L?.4 h-
"Lllft~~~~
L.l. f:l+ ~:; +fJ~ .
: I : . : . ill I I I I I m t I " " "! i _ J . ,. . I Positive Camber I~) H 1-1 I I II II ~ t ,I. L LLLu....L1 143 720
Camber
Diagram shows correct Camber (fj) in relation to position of
lower links (a).
Examp le: angle of lower link is +2°, correct Camber is
0 .05 ° (negative Camber). Tolerance = ±0.25°.
143721
155
·ltl III ·ltl It •. ·ltl III ·ltl 'It ·It '

70019401960 Specifications
Section
6 Suspension and steering
A
Toe-in
Meas ured as ang le
Toe -in ( ----------.-.--..---Spec ificat ion
Toe-in measurement (B-A) should be is 0.5±0.8 mm, mea ­
sured at C, see left.
Note: Camber must always be adjusted before Toe-in.
Toe-in tolerance
B 143 724
Measure Toe-in of unladen vehicle, according to above .
Apply sufficient load to obtain a lower link angle of 8°± 1 o .
Repeat Toe-in measurement and compare results.
Max. difference = 3' per wheel.
-c
143723
Group 61 Front wheel suspension
Tightening torque -85 Nm (63 ft. Ib)
95 Nm (70 ft Ib)
~~-.'"
~~======~~C r~M12: 85 Nm (63 ft Ib) ~:./ M 14: 140 Nm (102 ft Ib)
135 398
Nm ft Ib
Control arm to ball joint , nut .................................. . 60 44
Ball joint to spring strut + 1/4 turn .............. ................ . 30 22
Steering rod to steering arm .......................... (approx.) 60 44
Upper bearing -body ............................... (approx.) 40 29
Upper bearing -shock absorber, -1984 ............... (approx .) 150 111
1985- .... ........... (approx.) 70 50
Front crossmember to body. . . . . . . . . . . . . . . . . . . . . . . . . . (approx.) 95 70
Whee l nuts ......... .. ................................ .. ... . . 85 63
Front wheel hub -stub axle +450 angle -tightening
nut
(1988-models) ................................. . ....... . 100 74
156
143 722

(
70019401960 Specifications
Section 6 Suspension and steering
Group 64 Steering
Steeri ng gear
Cam gear
Numbers of turns, lock to lock ...................... .......... .
Steering ratio .
.............................................. .
Clearance between pre-tensioning piston and cover ............. .
Frictional torque, measured on input shaft ...................... .
Checking servo
balance:
pump pressure when measuring steering wheel torque ........ .
torque
on steering wheel . ............................. ..... .
max deviation between right and
left locks ................... .
Lubrication, type
............................................ .
quantity .
........................................ .
Hydraulic fluid ..... .... ..................................... .
/
ZF
Numbers of turns, lock to lock ................................ .
Steering ratio
............................................... .
Clearance between pre-tensioning piston and cover ............. .
Frictional torque, measured on input shafl. ..................... .
Checking servo
balance:
pump pressure when measuring steering wheel torque ........ .
torque un steering
wheel ................................... .
max deviation between right and
left locks ................... .
Lubrication, type
............................................ .
quantity
........................... .............. .
Hydraulic fluid .............................................. .
Servo pump
132 430 136 000
A B
Max
pressure, early type (A, B,C) ............................ . .
late type of "C" ....... .... ..................... .
type
"0" ................... .... 0-' .•• •••••.••...
960 , B 6304 F ................................. .
132429
3 .5
16.9:1
0.0~.12 mm
0.6-1.7 Nm
0 .0019-0.0047 in
5.3 in. lb.
1.2 MPa 171 psi
3 .5-4.5 Nm 31-40 in. lb.
1 Nm 9 in. lb.
Grease, Volvo PIN 1161001-1
100
grams
See page 14
3.5 16.9:1
0.025-0.05 mm
0.6-2.1 Nm
0.0010-0.0020
0.4-1.5 ft Ib
1.2 MPa 171 psi
3.4-4.5 Nm 31-40 in lb .
1 Nm 0.7 ft Ib
Grease Volvo PIN 1 161 001-1
100
grams
See page 14
C
7 .6-8.3 MPa
9 .3-10.0 MPa
10 .0-11.0 MPa
9.3-10.0 MPa
D
1081-1180 psi
1323-1422 psi
1422-1564 psi
1323-1422 psi
157
I

70019401960 Specificatidns
Section
6 Rear wheel suspension
Tightening torques
Nm ftlb
Steering column 760 1988-............................. .. ... .
24 17
Steering wheel nut .
........ ................................. . 34
25
Steering column, universal joints
.............................. .
24 17
Steering gear -
cr 44 32
Steering
rod - outer ' ball joints ........................ (approx .) 70 52
Steering arm -outer
ball joints ........................ (approx.) 60 44
Group 65 Rear wheel suspens ion
Tightening torques (Multi-link)
Nm ft Ib
Link to lower , wheel beBring housing, nut +900~ngle tighten ..... . 50 37
Link to
lowen'rear axle crossmember, nut +900 angle tighten ..... . 50 37
Stud to body ................................................ .. . 70 51
Support arm mount lto body, nut +900 angle tighten ............. . 70 51
Support arm to body, bolt .................................... . 48 35
Support arm to mount, nut + 1200 angle
tighten ................. . 125 91
Support
arm to wheel bearing housing, bolt +90 angle tighten ... . 60 44
Link to upper wheel bearing housing, nut ...... ................ . 115 83
Link
to rear axle upper front crossmember, nut +600
angle tighten ............................................. . 70 51
Link to rear axle upper rear crossmember, nut .................. . 85 61
Track rod to wheel bearing housing, bolt ..................... .. . 85 61
Track rod to rear axle crossmember, nut ....................... . 70 51
Rear axle crossmember (front) to body, bolt +600 angle tighten .. . 70 51
Rear axle crossmember (rear) to body, bolt +600 angle tighten ... . 70 51
Final drive (front) to rear axle crossmember, bolt ................ . 160 116
Final drive (rear) to rear axle crossmember, bolt
................ . 160 116
Cable bracket to rear axle cross member, nut
................... . 24
17
Shock absorber to support arm, nut ........................... . 56 41
Shock absorber to body, bolt ................................. . 85 61
Wheel stud to shaft +600 angle tighten ........................ . 140 102
Wheel
bearing housing buffer, nut. ............................ . 24 17
Backplate to rear wheel bearing housing, bolt
.................. . 24
17
Brake caliper to wheel bearing housing, nut ..
.................. . 60 43
158