Replacing the right drive shaft pilot bearing: Reassembly

WARNING: This page does not describe the selected car, but rather 8 other vehicles, including the 2006 Volvo S80, 2005 Volvo S80, 2004 Volvo S80, 2003 Volvo S80, and 2002 Volvo S80. However, it is still accessible from the selected car via links, so may be relevant.

Assemble the inner joint

Fig 1: Positioning Outer Section Of Shaft Vertically In A Vice

Courtesy of VOLVO CARS OF NORTH AMERICA.

Use measurements according to Clean and mark up the constant velocity joint .

Position the outer section of the shaft vertically in a vice.

Lubricate the constant velocity joint ball track. Also apply grease in the bottom of the housing.

Use half of the grease in the joint. The rest of the grease will be used in the boot, see Apply grease in the boot .

Hold up the ball holder so that the balls are as high up as possible without falling in towards the middle.

Hold the balls in this position.

Install the inner section of the shaft

Fig 2: Installing Inner Section Of Shaft With Universal Joint

Courtesy of VOLVO CARS OF NORTH AMERICA.

Carefully install the inner section of the shaft with the universal joint according to the markings made previously. See Clean and mark up the constant velocity joint . Press the shaft sections together.

Position the shaft assembly horizontally.

Apply grease in the boot

Fig 3: Securing Inner Section Of Shaft In A Vise

Courtesy of VOLVO CARS OF NORTH AMERICA.

Secure the inner section of the shaft in a vise.

NOTE: Take care that the joint does not separate.

Apply the rest of the grease (from the tube) in the boot. Ensure that there is no grease on the mating surfaces between the boot or the drive shaft and the constant velocity joint. Clean off excess grease with denatured alcohol.

Press the boot onto the constant velocity joint

Fig 4: Installing New Clamp Using Pliers 951 2619

Courtesy of VOLVO CARS OF NORTH AMERICA.

Ensure that it is in position.

Install the new clamp. Use pliers 9512619 .

Check that the boot is in position on the drive shaft

Fig 5: Inserting Screwdriver Between Drive Shaft And Boot

Courtesy of VOLVO CARS OF NORTH AMERICA.

Use a well rounded screwdriver.

Carefully insert the screwdriver between the drive shaft and boot. Ensure that the boot is in position on the drive shaft (the inner rib against the joint).

Install a new clamp. Use pliers 9512619 .

Install the drive shaft in the transmission

See Install the drive shaft in the gearbox, the stub axle and the control arm .