Front Cross-Member: Service and Repair

Replacing the cross member

Preparations
Raise the car so that both wheels are unimpeded.

Remove
- the heat deflector plate in front of the output shaft
- the front splashguard for the engine.

Remove the central front-rear member





Remove
- The nuts from the engine mountings at the front and rear edges
- the four screws (2 long and 2 short)
- the two screws from the engine mountings. Remove the central front-rear member.

Remove the front exhaust pipe





Remove:
- the wiring for the heated oxygen sensor (HO2S) from the connector.
The oxygen sensor (O2S) does not need to be removed if the front exhaust pipe is hung up
- the rubber mounting for the muffler
- the bushings (D4192T)
- the mounting for the exhaust manifold.

Disconnect the gear selector lever from the transmission




Remove the screw. Remove the plastic spacers. Remove the O-rings.

Remove the steering gear housing from the cross member





Remove:
- right-hand drive cars: the threaded end on the right from the manifold
- the screw. Slacken off the heat deflector plate and twist it to remove it
- the two screws from the pipe bracket on the cross member
- the four mounting screws from the steering gear housing
- The brackets. Remove the steering gear housing.

Remove the control arms from the anti-roll bar




Remove the nut by locking the ball joint with an Allen key.

Remove the control arm from the cross member
See step Control arm and control arm bushings, replacing Control Arm And Control Arm Bushings, Replacing.

Remove the cross member




Support the cross member. Remove the two screws. Remove the cross member

Replace the anti-roll bar on the cross member
See step Removing and installing the anti-rollbar link Removing And Installing The Anti-Rollbar Link.

Install the cross member




D4192T: If necessary, transfer the bushing for the exhaust pipe mounting.
Clean the mating surfaces thoroughly.
Install the cross member. Install the two front (long) screws. Tighten these two screws by hand.
Position the steering gear housing. Install the control arms loosely on the cross member.
Also replace the locknut for the front pin bolt on the control arm. Do not tighten the locknut yet.
Position the cross member.
- the long screws at the front edge. Tighten to 90 Nm
- the short screws at the rear edge. Tighten to 90 Nm.

Secure the steering gear housing on the cross member




Position the steering gear in its mountings.
Install the brackets and the screws. Tighten to 69 Nm.
Ensure that the bracket and the mounting in front of the heat deflector plate are in the correct position.
Install the pipe mounting and the screws on the cross member. Tighten to 25 Nm.
Install the heat shield. Tighten to 10 Nm.
Check that the clamps are correctly positioned.

Reinstall the gear selector lever in the transmission




Apply Volvo grease P/N 1161241-3 on the bearing.
Install new plastic spacers and O-rings.
Install the screw. Tighten to 16 Nm.

Install the front exhaust pipe




D4192T: Position the right threaded end in the manifold.
Tighten to 15 Nm.
Position the pipe. Install the springs and screws.
Use new gaskets.
D4192T: Install the bushing on the cross member. Install the screws. Check the sleeve and the rings for the seat.
Tighten to 13 Nm.

Tighten to:
- the nut for the front exhaust pipe: 9 Nm
- The screws between the exhaust pipe and the three-way catalytic converter (TWC): 35 Nm.

Install the central front-rear member




Install the central front-rear member on the front engine mounting. Press the engine forward. Secure the central front-rear member on the rear engine mounting.
Install the four screws for the central front-rear member. Tighten to 69 Nm.
Tighten the screws in the engine mountings. Tighten to 55 Nm.

Install:
- the front splashguard for the engine
- the heat deflector plate for the output shaft. Tighten to 10 Nm.

Install the control arm




Remove the support and rock the car a few times so that the bushings come into the correct position.
Tighten the pin bolt nut. Tighten to 90 Nm + 60°.

Secure the control arms on the anti-roll bar




Use new nuts for the ball joints.
Tighten to 45 Nm.