lock VOLVO 960 1982 Service Service Manual

I
I
70019401960 Specifications
Section
4 Power Transmission
Gove rnor pressure
3.54:1
Speed Pressure Speed
35 km/h 0
.11- 0.17 MPa 30 km/h
(22 mph) (15
.
6-24.2 psi) (19
mph)
55 km/h 0.17-0.23
MPa 55 km/h
(34 mph) (24
.
2-32.7) (34 mph)
110 km/h 0.38-0.50 MPa 108 km/h
(69 mph) (54
.1 -71.1 psi) (67
mph)
* Only for AW 72.
Shift speeds km/h (mph)
Eng in e Type Rear ax
le
ratio
B 19 E AW70
3.
91 :1
B23E AW71 3
.73:1
B23FT AW71 3.73:1
B28A AW71 3.54:1
B28E AW71 3.54:1
B28F AW7 1 3 .54 :1
B200 F AW70 4.10:1
B200E AW70 3.91 :1
B200 K AW70 3.91 :1
B230 A AW71 3.73:1
B230K -19 86 AW71
3.91 :1
B230 K 1987 - AW71
3.91 :1
B230 F2
) AW70 4.10:1
B 230 F 1989-3
) AW70 4.10:1
B230FT AW71 3.73:1
B
230 FT/GT 1990 AW71 3.73:1
B234F AW72 4.10:1
B280E AW71 3
.91 :1
B280 F AW71 3.73:1
Throttle
valve opening %
1) Kick-down .
Rear axle r ed uction ratio
3.73:1 3.91:1
P r
essure Speed Pressure
0.09- 0.15 MPa 29 km/h 0 .09-0.15 MPa
(12.8-21.3 psi) (18
mph) (12
.8-21.3)
0.16-0.22
MPa 53 km/h 0
.16-0.22 MPa
(22 .8-31 .3 psi) (33
mph) (22
.8-31.3 psi)
0.41-0 .
53 MPa 103 km/h 0.41-0.53 MPa
(58.3-8.4 psi) (64 mph) (58
.3-8.4 psi)
1
-2 2-3 3-4 4-3
62 (39) 103 (64) 109 (68)
38 (24)
63 (39)
105 (66) 135
(84)
39 (24)
63 (39)
105 (66) 111 (69) 39 (24)
73 (46) 123
(77) 123 (77) 28 (24)
67 (42) 112 (70) 119 (74)
29 (24)
67 (42) 112
(70) 119 (74) 29 (24)
57 (36)
101 (63) 110 (69)
37 (23)
67 (42) 113
(71) 114 (71) 40 (25)
67 (42) 113 (71) 114 (71) 40 (25)
71 (44) 119 (74) 118 (74)
27 (17)
66 (41)
111 (69) 112 (70) 35 (22)
55 (34) 98 (61) 107 (67)
35 (22)
63 (39)
106 (66) 108 (67)
37 (23)
57 (36) 99 (62) 110 (69)
36 (23)
63 (39) 105 (66) 111 (69) 39 (24)
65 (41) 112
(70) 130 (81) 27 (17)
56 (35) 102 (64) 116 (73) 33 (21)
60 (38) 105 (66) 116 (73 )
44 (28)
63 (39) 110 (69) 121 (76)
46 (29)
1001) 1001
) 75 0
2) USA/Canada estate cars -1988, 1989-: other markets . 3) USA/Canada/Japan! Australia 1989-.
Mechanical lock-up B230 K
Engages
at ......................... ... ........... km/h (mph) 85 (53)
Disengages at
.................................... km/h (mph) 83 (52)
* Applies to 1 208652 . 1 208604 77 (48), 73 (46). "Applies to 1208643.
144
B230F
78 (49)
76 (47)
Speed
27 km/h
(17 mph)
25 km/h *
(16 mph)
50 km/h
(31 mph)
45 km/h *
(28 mph)
98 km/h
(61 mph)
95 km/h *
(59 mph)
3-2
97 (61)
99 (62)
99 (62)
115 (72)
106 (66)
106 (66)
94 (59)
107 (67)
107 (67)
111 (69)
105 (66)
91 (57)
100 (62)
93 (58)
99 (62)
106 (66)
93 (58)
99 (62)
104 (65)
1001
)
B230F*
1989-
9230 FB
B234F
86 (54)
84 (53)
4.10:1
Pressure
0.09-0.15 MPa
(12.8-21.3 psi)
0 .
16-0.22 MPa
(22 .8 -
31.3 psi)
0.41-0.53
MPa
(58 .3-8.4 psi)
2-1
49 (31)
50 (31)
50 (31)
58 (36)
53 (33)
53 (33)
46 (29)
55 (34)
55 (34)
56 (35)
55 (34)
44 (28)
52 (32t
45 (28)
50 (31)
54 (34)
41 (26)
49 (31)
51 (32)
1001
)
B230 FT""
95 (59)
90 (56)

(
(
Tightening torques
AW70, AW71, AW72
Converter casing -engine, M 10 ...................... .. ...... .
M12 .................. ......... .. . .
Drive plate
to torque converter ................... ............. .
Centre support to gear case:
tighten alternately
in steps to 7 Nm (5 ft Ib) ............... ... .
Pump cover to pump body .......................... ......... .
Pump assembly to gear case .............. ................... .
Plate above parking pawl ............................. ....... .
Converter casing gear case
4
x M 10 ................................ ................. .
2 x M 12 ..
.............. ................................. .
Rear extension housing to gear case
.......................... .
Valve bodies, for cam M 6 .................................... .
other bolts, M 5 ...
.............................. .
Oil strainer to lower valve body ........... .. ............ ...... .
Cover plate
to gear case, M 6 ................................ .
Valve body to gear case ..................... .......... ..... . .
Oil pan to gear case .......... ........ ..................... .. .
Coupling flange
to output shaW .................... ........... .
Blind plug for pressure test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..
... .
Nut, oil cooler to gear case .
.................................. .
Speedometer drive
................... .................. ..... .
Nut, oil dipstick tube
........ ................................. .
Solenoid valve
.................... .. ........................ .
Drain plug
to oil pan ........................................ . .
• Use locking fluid PIN 1161 053-2 (1161 054-0) .
Nm
35-50
55-90
41-50
24-28
6-9
22-28
6-9
27-42
48-68
27-47
6-9
5-6
5-6
6-9
8-12
4-5
40-50
5-9
20-30
4-6
65-70
10-16
18-23
70019401960 Specif ications
Section
4 Power Transmission
ftlb
(25-36)
(40-65)
(30-36)
(17-20)
(4-6)
(16-20)
(4-6)
(20-30)
(35-49)
(20-34)
(4-6)
(3.5-4)
(3.5-4)
(4-6)
(6-9)
(3-3.5)
(30-36)
(3.5-6)
(14-22)
(3-4)
(47-51)
(7-12)
(13-17)
145
II
" II ., II ' . .. • • ..

(
7001940/.960 Specifications
Section 4 Power Transmission
Gear shift speeds, km /h (mph)
Mode selector in position ECONOMY (E). Sh ift selector in position D. Thro ttle opening in %
Engine Type Final drive 1-2 2- 3 3-4
3-4 4-3 3-2 2-1
ratio
(100+KD) (100+KD) (75) (100+KD)
(100+KD) (100+KD) (100+KD)
B6304F AW30--43 3.73:1 58 114
157 180 175 105 45
Mode selector in position SPORT (S). Sh ift selector in pos ition D. Thrott le open ing in %
Eng ine Type F
inal drive 1-2 2-3 3-4 3-4 4-3 3-2 2-1
ratio
(100+KD) (100+KD) (75) (100+KD) (100+KD)
(100+KD) (100+KD)
B6304F AW3D-43 3.73:1 58 114 177 180 175 105 45
Mode selector in position WINTER (W). Shift se lector in pos ition D. Thrott le open ing in %
Eng ine Type F
in al drive 1-2* 2-3* 3-4
3-4 4-3 3-2* 2
-1*
rat io (100+KD) (100+KD) (0-100)
(100+KD) (0-100)
(100+KD) (100+KD)
B6304F AW3D-43
3.73:1 50 100 50 170 40 70 20
* 1st and 2nd gear only used on kick-down .
Mechanica l lock-up (LOCK-UP), km/h (mph). Shift selector in pos ition D. Thrott le open ing in %
ECONOMY (E ) SPORT (S ) WINTER
(W)
Eng
ine Type Fin
al drive 2 3 4 2
3 4 3
ratio
(100+KD) (100+KD) (100+KD)
(100+KD) (100+KD) (100+KD) (15-98)
in out in out in out in out in out in out in out
B6304F AW3D-43 3.73:1
85 1 77 130 1123 180 1175 85 1 77 130 1123 180 1175 50 1 40
147
I
III 'II III II III
,II
W · III

700/940/960 Specifications
Section
4 Powe r Transmission
Components
Contro l unit
-Volvo part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515646
ShiH position sensor
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515639
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740153
Mode se lector
-Volvo part number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515640
Solenoids :
ShiH solenoid
1 (51) and 2 (52)
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515643
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740040
Resistance at +25°C (7rF). . . . . . . . .. ... . . . . . . . . .. . . . . .. . . . . .. 13±20
Lock-up so lenoid (SL)
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515644
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740041
Resistance at +25°C (7rF) ............. " . . . . . . . . . . . . .. . . .. . . 13±20
Line pressur e sole noid (5TH)
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515645
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903457389
Resistance at +25°C (7rF). . . . . . . . . . . . . ... . .. ..... . . . . ... .. . . 13±20
Speed sensor
-Volvo part number ... ..-: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515641
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740151
Oil te mp eratur senso r
-Volvo part number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3515642
- Aisin Warner number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9903740154
Resistance at
+160°C (320°F)......... .. .... . ......... ....... .............. 20.7±2.90
-O°C (32°F) .. . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . .. . . .. . . . .. . . . . . . 2067±396 0
20670
Tightening torques
Nm (ft Ib)
Converter casing -engine, starter motor (2 pcs) ................ . 40.0 30 others .............. ............... . 48.0 35
Drive plate -torque converter ................................ . 30.0 22
Coupling flange to output shaft ............................... . 50.0 36
Plug, oil pan ................................................ . 20.0 14
148

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)

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
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
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