Volvo Car USA LLC

Technical Journal

Technical Journal Title

Ref. No.

Long Range PHEV ERAD Knocking Noise Repair Kit

TJ 36894.5.1

Issuer (Dept.)

Issue Date

Status Date

12/3/24

12/4/24

Technical Service
Car Market

Partner

Function Group

United States and Canada

3 US 7510 Volvo Car USA

4632

Function Description

Page

Electrical rear axis drive

Page 1 of 13

Rows beginning with * are modified
Note! If using a printed copy of this Technical Journal, first check for the latest online version.

Attachment
File Name

File Size

Step-by-Step Repair Instructions TJ 36894.pdf

0.0492 MB

TJI-528981-1_1_9_en-US (1).pdf

2.8956 MB

DESCRIPTION:
*Updated info about the Torx socket
If a customer notices a knocking noise from the ERAD during acceleration or deceleration at low
speeds, please follow the advice under “Service.”
ERAD = Electric Rear Axle Drive
PHEV = Plug-In Hybrid Electric Vehicle

CSC Customer Symptom Codes
Code

Description

8N

Driving/Unusual noise/Unsure when/at all times

F2

Driving/Unusual noise/During acceleration

ZE

Idling/Unusual noise

D2

Front/rear axle/Unusual noise

DTC Diagnostic Trouble Codes
Vehicle Type
Type

Eng

Eng
Desc

Chassis
range

Struc Week
Range

224

H6

BH6PHEV

2022-2023

-

202147-202307

225

H6

BH6PHEV

2022-2023

-

202147-202307

238

H6

BH6PHEV

2022-2023

-

202201-202307

246

H6

BH6PHEV

2022-2023

-

202147-202307

256

H6

BH6PHEV

2022-2023

-

202147-202307

Sales

Body

Gear

Steer

Model Year

Plant

Technical Journal 36894.5.1
SERVICE:
First please watch the attached video to ensure the customer’s vehicle makes the noise addressed in
this technical journal.
A repair kit is now available instead of replacing complete ERAD units for this issue.
•

Please order part number 32411580 and follow the attached instructions.

NOTE: The gaskets included in the repair kit are only necessary to replace if damaged. Also, grease
and abrasive cloth are not included in the kit and must be ordered separately (PN 1161748 and
9511024).
NOTE: A T30 5-point security Torx socket (aka Pentalobe Security bit) is required for this repair.
NOTE: In cases where the bearing is stuck in the cover, also order the new Bearing kit part
number:32411722. (When this repair is performed claim op 98587-3.)

Warranty claim info:
To get a warranty claim accepted for a job described in this TJ, use the corresponding VST OP
number stated in this TJ.
Note that the TJ number must be stated in the repair order text.

VST Operation Number
VST Operation Number

Description

98298-2

Bearing, ERAD, cleaning acc. to TJ

97733-3

High voltage battery disconnect/connect and insulation measurement acc. QB/TJ

98587-3

Bearing, ERAD, replace acc. to TJ

VEHICLE REPORT:
Yes, please submit a Vehicle Report if the service solution described in this TJ has no effect. Use
concern area “Vehicle Report” and sub-concern area “Support Needed,”, use function group 4632.

To view TJ attachments continue to next page. This TJ has two attachments.

Page 2 of 13

2024-12-04

Overview
This noise is a result of corrosion on a bearing race surface. The typical repair procedure is to remove the
covers, clean the bearing surfaces, apply grease, and reassemble. The gaskets are provided in case they are
needed. In rare cases the resolver wheel may be found to be loose, or the bearing is stuck in the housing, in
this event, the bearing kit must be ordered.
Disassembly
The top rectangular cover is removed first. A gasket for this cover is included in the kit, but it only needs to be
replaced if the original one is damaged. Underneath this cover is a wire clip (also included in the kit) and two
connectors that need to be disconnected.
Next, remove the smaller side cover, a gasket is included for this cover as well. Again, it is only necessary to
replace if the original gasket is damaged.
Next, remove the larger side cover which the previous piece was bolted to. A gasket is included for this cover
as well. Again, it is only necessary to replace if the original gasket is damaged.
Bearing Replacement:
Note: This section is only followed if the bearing remains in the side cover and/or the 4 lobed clover resolver
wheel was removed from the shaft or appears to be loose.
Order Bearing Kit part number 32411722. This kit includes one replacement bearing and one 4 lobed resolver
wheel.
To remove the bearing from the side case, place the side casing in a hydraulic press. Support the bottom of
the side case using special tool 999 7095. Press the bearing out of the cover using tool 999 7176 or
equivalent.
Install the new bearing on the shaft using special tool 999 7542.
Install the resolver wheel on the shaft using special too 999 7546.
Repair
Remove the "wave" type washer from the inside of the large side cover.
Using abrasive cloth (not included in the kit) clean any corrosion from the outside surface of the bearing.
Ensure there are no bits of abrasive cloth left after cleaning.
Repeat the process on the bearing mating surface inside of the large side cover.
Apply a thin and even layer of grease (not included in the kit) to both surfaces which were just cleaned.
Reinstall the "wave" type washer on the inside of the large cover.
Reassembly:
Reassemble in reverse order of disassembly, taking note of the torque specs listed during the disassembly
instructions.

Volvo Car Customer Service

Title

ERAD bearing

Action

TJ Instruction VCC-528981-1

Product fix

Page

1 ( 10 )

Operation number:

98298-2
97733-3

Issue
1

Date
2024-04

Model year
2022, 2023
2022, 2023
2022, 2023
2022, 2023
2022, 2023
2022, 2023
2022, 2023

Reason
Technical content change

Affected vehicles

Model
S60 (19-)
S90 (17-)
S90L
V60 (19-)
V90 (17-)
XC60 (18-)
XC90 (16-)

Materials
Abrasive cloth
Splines grease

Description
Socket
Drift
Counterhold
Drift

Designation
Hydraulic press
Copper mallet

Transmission
TG-81SD
TG-81SD
TG-81SD
TG-81SD
TG-81SD
TG-81SD
TG-81SD

Qty.
0.3
0.5

Materials

Part No.
9511024
1161748

Special tools

Part No.
999 7095
999 7176
999 7542
999 7546

Equipment

Part No.

Notes
Consumable;

TJ Instruction VCC-528981-1

Page 2 ( 10 )
Color symbols

Note! This colour chart displays (in colour
print and electronic version) the importance
of the different colours used in the images
of the method steps.
1 . Used for focused component, the
component with which you will do
something.
2 . Used as extra colors when you need to show
or differentiate additional parts.
3 . Used for attachments that are to be
removed/installed. May be screws, clips,
connectors, etc.
4 . Used when the component is not fully
removed from the vehicle but only hung to
the side.
5 . Used for standard tools and special tools.
6 . Used as background color for vehicle
components.
Removal
Remove electric rear axle drive ERAD , refer
to:
Removal, replacement and installation
4 - Power transmission
46 - Rear axle, drive shafts
465 - final drive (front and rear)
Remove the screws.
Remove the marked part.
Torque:
High voltage wiring harness lid, ERAD ,
9 Nm

TJ Instruction VCC-528981-1

Page 3 ( 10 )
Disconnect the connectors.
Loosen the fastener.

Caution! Take extra care when handling the
components.
Remove the screws.
Remove the marked parts.
Torque:
Inner shaft lid screw, ERAD , 23 Nm

TJ Instruction VCC-528981-1

Page 4 ( 10 )
Caution! Take extra care when handling the
component.
Remove the screws.
Remove the marked part.
Torque:
Electric motor cover screw, ERAD , 23 Nm

Caution! If the component is loose, a new
component must be installed.

TJ Instruction VCC-528981-1

Page 5 ( 10 )
The following steps apply if damages are
discovered

Note! Orientation view

Install the Special tool.
Special Tool: T9997095, Socket
Special Tool: T9997176, Drift
Use: Hydraulic press

TJ Instruction VCC-528981-1

Page 6 ( 10 )
Install the marked component.
Special Tool: T9997542, Counterhold
Use: Copper mallet

Note! Orientation view

TJ Instruction VCC-528981-1

Page 7 ( 10 )
Install the marked component.
Special Tool: T9997546, Drift
Use: Copper mallet

Continue the removal following the steps below.
Remove the marked part.

TJ Instruction VCC-528981-1

Page 8 ( 10 )
Caution! Make sure that the surface is clean
and free of foreign material.
Clean the marked area.
Use: Abrasive cloth , 9511024

Caution! Make sure that the surface is clean
and free of foreign material.
Clean the marked area.
Use: Abrasive cloth , 9511024

TJ Instruction VCC-528981-1

Page 9 ( 10 )
Installation
Apply grease on the area indicated.
Apply a thin and even layer.
Use: Splines grease , 1161748

Install the marked component.

TJ Instruction VCC-528981-1

Page 10 ( 10 )
Apply grease on the area indicated.
Apply a thin and even layer.
Use: Splines grease , 1161748

To install, reverse the removal procedure.