SP 722-001 Service Bulletin/Repair Instructions

Vo l v o Tru c k s N o r t h

A me ri c a

Greensboro, NC USA
S ervic e P rogram

Tr u c k s

Date
11.2012
Group
No.
722 001
Release
Page
1
1(33)
Upper Torque Arm, Air Disc Brake,

Replacement

VN
S P 7 2 2 -0 0 1 , U p p e r To r q u e A r m , A i r D i s c B r a k e ,

Replac ement

(N ov emb er 2 012)
N o t e : Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual vehicle being

serviced. However, key components addressed in this information are represented as

accurately as possible.

This bulletin is intended to assist service technicians with the installation of Volvo Service Kit

No. 21951871 This bulletin also includes instructions for rear suspension alignment for select

Volvo vehicles, equipped with air disc brakes and Hendrickson’s tandem PRIMAAX® EX 462

(PAX EX) suspension originally installed by Volvo.

A number of Volvo vehicles were built between December 1, 2010 through May 1, 2012 with

the Hendrickson PRIMAAX EX suspension adapted by Volvo to accommodate air disc

brakes. Upon review of some of these units it has been determined that some operation and

service concerns may exist, which should be reviewed.

In general, the PRIMAAX EX suspension may require spacers to be installed between the

longitudinal torque rods and frame hanger brackets to assure pinion angles and alignment

are correct. In some cases these spacers may not have been correctly specified and/or

installed correctly on the vehicles at the time of assembly. If so, this could cause the pinion

angles and/or alignment to be incorrect. New spacers are provided in Volvo Service Kit No.

21951871 to correct this potential condition. Regular maintenance inspection procedures, as

referenced in Hendrickson Technical Publication number 17730-254 will still be required to

help ensure the adjacent joint retain their proper torque over time.

It has also been reported on some of these vehicles:
•

•
Shock travel may be too long allowing the suspension to over travel
•
Some longitudinal torque rod bushings may be improperly centered which can cause

contact with and accelerated wear to the top pads
Some chassis fasteners may be too long which may result in rubbing on vehicle

components
Any such conditions should be completed with Volvo Service Kit No. 21951871 and proper

maintenance to assure optimum performance.

Contact Volvo Tech Service at (866) 238-6586 for further information regarding this

campaign.
USA55596
P V 7 29-SP722-001

English
Vo l v o Tru c k s N o r t h A m e r i c a

S e rv ic e P ro gra m
Date

11.2012
Group
No.
Release
722
001
1
This bulletin is to assist service technicians in the installation of Volvo Service Kit

No. 21951871 which is intended to:
•
Replace the factory installed torque rod to frame hanger open-end shim(s) with closed-end

shim(s) (Part Numbers. 70240-001 and 70240-002) and/or torque rod spacer (Part

Numbers. 67057-001, 67057-002, 67057-003, and 67057-004) connection as needed.
•
Inspect and/or component replacement of the:

● Longitudinal Torque Rods

● Top Pad

● D-Pin bushings (may require additional components not included in Volvo Service Kit

No. 21951871)

● Bottom caps (may require additional components not included in Volvo Service Kit No.

21951871)

● Shock Absorber
•
Inspection of the U-beam assembly and if necessary component replacement D-Pin

bushings and/or bottom caps (may require additional components not included in Volvo

Service Kit No. 21951871)
•

•

•
Normal warranty guidelines apply

Time not included in Service Program for D-Pin bushing replacement

Axle alignment
Refer to Hendrickson Technical Publication number 17730-254 for complete service and

safety instructions regarding PRIMAAX EX for Volvo vehicles, available online at:

www.hendrickson-intl.com.
Page

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Vo l v o Tru c k s N o r t h A m e r i c a

S e rv ic e P ro gra m
Date

11.2012
Group
No.
Release
722
001
1
Vo l v o S e r v i c e K i t N u mb e r 2 1 9 5 1 8 7 1

P art N u mber
De sc riptio n
Quantity
60657-007
Shock Absorber
4
70240-001
Shim 3.04 mm
12
70240-002
Shim 1.52 mm
12
60961-653
Pinion Spacer Service Kit,

Includes 4 of each:

Pinion Spacer 4.0 mm

Pinion Spacer 8.0 mm

Pinion Spacer 12.0 mm
1
50754-008
Shock Fastener Service Kit
1
Torque Rod / Frame Hanger

Fastener Service Kits

49176-032
8.0 i.n Bolt Kit
2
49176-039
9.0 in.Bolt Kit (Includes 4 of

16.0 mm pinion spacers)
2
60632-012
QUIK-ALIGN® Service Kit
2
Torque Rod / Top Pad

Service Kits

68821-151
Left Hand Front
1
68821-152
Right Hand Front
1
68821-351
Left Hand Rear
1
68821-351
Right Hand Rear
1
48718-128
U-bolt Service
2
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Vo l v o Tru c k s N o r t h A m e r i c a

S e rv ic e P ro gra m
Date

11.2012
Group
No.
Release
722
001
1
Repair Procedure

L ATE R A L A L I G N M E N T

1 Use a work bay with a level surface.

2 Relax the suspension by slowly moving the vehicle back and forth several times in a

straight line without using the brakes. This will slacken or loosen the suspension as the

vehicle is positioned. End with all wheels positioned straight ahead.

3 D O N O T set the parking brake. Chock the front wheels of the vehicle.

4 Verify and maintain the air system at full operating pressure.

5 Ensure all drive axle tires are the same size and properly inflated.

6 Verify all suspension components are in good condition. Repair or replace any worn or

damaged suspension components before proceeding with the alignment process.

7 Verify the vehicle is at the correct ride height, see page 28 S E T V E H I C L E TO R I D E

H E I GH T Section.

8 Measure from the outside of the frame rail to the rim flange of the inner tire. Record the

measurement.

9 Measure the same distance on the opposite side of the same axle. Record the

measurement.

10 Subtract the two measurements to get a difference between the two. If the difference is

greater than 3 mm (0.125 in.), it will be necessary to correct the lateral alignment. Adding

or removing shims that are located between the transverse torque rod and frame rail or the

axle tower will accomplishes this. A general rule of thumb is to use a shim with a thickness

that is half of the difference between the two measurements. For example, If the lateral

alignment is out of specification by. 6 mm (0.25 in.), remove or install a 3 mm (0.125 in.)

shim between the transverse torque rod and frame rail or axle tower as needed.

N o t e : Hendrickson recommends the use of Grade 8 bolts and Grade C locknuts for all

torque rod attachments.
S U P P O RT B E A M A N D B O T TO M C A P I N S P E C TI O N

INS P E CTI ON

1 Use a work bay with a level surface.

2 Relax the suspension by slowly moving the vehicle back and forth several times in a

straight line without using the brakes. This will slacken or loosen the suspension as the

vehicle is positioned. End with all wheels positioned straight ahead.

3 D O N O T set the parking brake. Chock the front wheels of the vehicle.

4 Verify and maintain the air system at full operating pressure.

5 Ensure all drive axle tires are the same size and properly inflated.

6 Verify all suspension components are in good condition. Repair or replace any worn or

damaged suspension components.

7 Verify the vehicle is at the proper ride height. See page 28 S E T V E H I C L E TO R I D E

H E I GH T in the Section.

8 Verify suspension lateral alignment is correct (Lateral offset = 0 mm / 0 in.).

9 Visually inspect the support beam to bottom cap location (inside the legs of the bottom

cap) for signs of contact.
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Vo l v o Tru c k s N o r t h A m e r i c a

S e rv ic e P ro gra m
Date

11.2012
Group
No.
Release
722
001
1
● If there is contact between the support beam and bottom cap due to D-Pin offset in the

support beam, replace the D-Pin. Center the D-Pin in the support beam ± 2 mm (0.02

in).

● Clearance between the support beam and the inside of the bottom cap legs should be

a minimum of 2 mm (0.02 in). If needed this will be corrected in the page 15 TOR Q U E

R OD / TO P PA D A S S E MB LY Section.

● Under normal operating conditions wear marks on the bottom cap may occur between

the raised section of the support beam and the bottom cap. This is acceptable, See

Figure 1, if gouges are more than 1 mm deep, replace bottom caps. See page 18

B O T TO M C A P R E P L A C E ME N T Section.

N o t e : Bottom caps are not included in service kit. If replacement is required, normal

warranty guidelines apply.
W7076425
Fig. 1

10 Repeat the support beam and bottom cap inspections for the remaining drive axles.

11 If D-Pin replacement is required for the affected U-beam assembly, proceed to the page 6

D - P I N R E P L A C E ME N T Section.

12 If all the axles have been inspected and D-Pin replacement is not required proceed to the

page 15 TO R Q U E R OD / TO P PA D A S S E MB LY in Section.
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Date

11.2012
Group
No.
Release
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D-PIN RE P LA CE ME NT

N o t e : D-Pin bushings are not included in service kit. If replacement is required normal

warranty guidelines apply.

YOU WILL NEED:
•

•
A vertical shop press with a capacity of at least 10160 kg (10 tons).

A D-Pin Removal Tool, Installation Tool, and Receiving Tool, see Figure 2.
D - P i n To o l s : These tools are designed to install and remove D-Pin bushing. Bushing tools

are made from cold rolled steel or equivalent. Drawings are for reference only. Hendrickson

does not supply these tools.
W7078099
Fig. 2

1 Installer

2 Remover

3 Receiver
Vo l v o Tru c k s N o r t h A m e r i c a

S e rv ic e P ro gra m
Date

11.2012
Group
No.
Release
722
001
1
R E M OVA L

1 Chock the front axle wheels.

2 Support the frame at ride height.

3 Raise the axle being serviced just enough to remove the wheels and support the axle.

4 Disconnect the height control valve(s) linkage assembly from the height control valve arm

(s), see vehicle manufacturer’s instructions.

5 Lower the leveling valve arm(s) to exhaust the air in the air springs and deflate the rear

suspension, see vehicle manufacturer’s instructions.

6 Lubricate the lower mounting fasteners of the air springs with penetrating oil. This will help

prevent the air spring mounting studs from damage during the removal process.

7 Remove the lower mounting fasteners from the air springs using H A N D TO OL S only, and

discard.

8 Remove both the lower air spring mounting brackets to disconnect air springs from the

cross tube, see Figure 3.

9 Loosen both QUIK-ALIGN fasteners, D O N OT remove at this time.
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Date

11.2012
Group
No.
Release
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001
1
W7076427
Fig. 3

1
Air Spring Assembly
2
Beam Notch
3
U-beam Assembly
4
1/2” Locknut (Tightening Torque 27-41 Nm (20–30 ft-lb)
5
Lower Mounting Bracket
6
Washer
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Vo l v o Tru c k s N o r t h A m e r i c a

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Date

11.2012
Group
No.
Release
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001
1
10 Install a floor jack with a 102 mm (4 in.) support plate to support the U-beam assembly.

11 Remove the D-pin fasteners on both sides of the axle and discard.

N o t e : It may be necessary to raise the front of the differential to allow the D-pins to

disengage the bottom caps.
WA R N I N G

The weight of the U-beam assembly is approximately 102 kg (225 lb). Care should be

taken at removal and installation to prevent personal injury or damage to components.

12 Lower the floor jack and pivot the U-beam assembly downward.

13 Remove the QUIK-ALIGN fasteners and discard.

14 Remove the QUIK-ALIGN eccentric and concentric collars.

15 Remove the U-beam assembly from the hangers.

16 Remove the U-beam assembly from the vehicle.

17 It is recommended that the U-beam assembly N O T B E disassembled.

I N S TA L L AT I O N

1 Place the U-beam assembly in a shop press on top of a receiving tool with both ends of the

support beam squarely supported on the press bed.

2 Mark the clocking position of the D-pin bushing on the support beam with a paint stick, see

Figure 4.

3 Install the D-Pin Removal Tool centered on the D-Pin bushing, see Figure 4.
W7076428
Fig. 4

A
Indexing marks
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Vo l v o Tru c k s N o r t h A m e r i c a

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Date

11.2012
Group
No.
Release
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001
1
4 Push directly on the D-Pin Removal Tool until the D-Pin bushing is pressed out of the

support beam bore.

5 Clean the support beam bore with a wire wheel.

6 Inspect the inner diameter of the D-Pin bore on the support beam, check for any damage

to the support beam bore. If the support beam bore is damaged, U-beam assembly

replacement is required, see the U-Beam Installation Section in this publication.

7 Lubricate the support beam D-Pin bore and the D-Pin bushing outer sleeve with chassis

grease, see Figure 5.
W7076429
Fig. 5

8 Line up the new D-Pin bushing with the clocking line that was put on the support beam,

see Figure 6.
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12 3

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