Volvo Technical Journal

TITLE: Replacement of ERAD components

"Right first time in Time"

Attachment

Vehicle Type

CSC Customer Symptom Codes

Technical Journal 33358.5.2

VST Operation Number: 98210-2

Description: ERAD transmission, replacement

DTC Diagnostic Trouble Codes

Rows beginning with * are modified

Note! If using a printed copy of this Technical Journal, first check for the latest online version.

DESCRIPTION:

*Updated vehicle types

To determine if the transmission or the complete ERAD needs to be exchanged follow instructions under "Service".

Instructional film is included as attachment, mp4.

The repair method is included as attachment, pdf.

Note: The ERAD (Electrical Rear Axle Drive) can almost always be repaired by replacing only the transmission. The complete ERAD rarely needs to be replaced.

SERVICE:

If the customer is driving in electric mode and experiences noise from the rear that increase with vehicle speed (that corresponds to the electrical motor speed), such as whining or howling, it is an electrical motor issue.

In this case the complete ERAD is to be exchanged. No DTC(s) are set for this issue.

If the customer experiences hesitation when the electrical motor should be engaged or no electrical motor engagement at all, the transmission part needs to be exchanged.

This fault may result in Clutch DTC(s) as indicated in the list, and a possible message in DIM (Driver Information Module) "Hybrid system failure, Service required".

ERAD transmission is ordered according to normal routines, Prior Approval is not necessary. ERAD transmission Part No. 32240142.

Note: Transmission oil is necessary to complete the repair and is not included in the repair kit. Please order in accordance with VIDA.

Technical Journal 33358.5.2

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 not needed”, use function group 4600.

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

Technical Journal 33358.5.2

TJ Instruction VCC-509127-1

Title: ERAD transmission

Action: Replacement

Issue: 1

Date: 2018-01

Reason: First issue

Page: 1 (19)

Operation number: 98210-2

Affected vehicles

Materials

Special tools

Equipment

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

Follow instructions for lifting points body frame refer to:

• Specifications, mechanical
• 8 - Body and interior
• 81 - Body frame
• 810 - general

Warning! Be prepared to collect escaping fluid. Remove the screw.

Caution! The fluid must be allowed to escape until a continuous flow changes into single drops.

Note! Make sure that the component is clean and free of foreign material. Remove the swarf.

Install the screw. Torque: ERAD Oil drain plug, 20 Nm

Remove rear axle, electric erad, refer to:

• Removal, replacement and installation
• 4 - Power transmission
• 46 - Rear axle, drive shafts
• 465 - final drive (front and rear)

Special Tool: T9997689, Fixture

Special Tool: T9992520, FLOOR STAND (TO FIXTURES) - Substitute with an appropriate stand as necessary

Remove the screw. Remove the cable harness clips. Remove the marked part.

Remove the screw. Lift the marked component up

Disconnect the connector. Remove the marked part.

Fold marked part to one side.

Turn the engine 90°

Remove the screws. (x12)

Note! Make sure that locating studs remains in the timing gear casing. Remove the marked part. Use: Plastic mallet

Old sealing. [trash-can-symbol]

Caution! Make sure that the wiring harness does not catch. Note! Note the position of the component before removal. Remove the part carefully. Remove the marked part.

Remove the marked part. Use: Plastic mallet

Old sealing. [trash-can-symbol]

Release the lock. Remove the marked part. Use: Circlip pliers [circlip-symbol] [circlip-pliers-symbol]

Note! Check the component. If any damage is shown, the whole complete ERAD is to be exchanged. Note! Make sure that the component is clean and free of foreign material.

Installation

Caution! Make sure that the component is positioned correctly. Install the catch. A click confirms that the component is in the correct position. Use: Circlip pliers [circlip-symbol] [circlip-pliers-symbol]

Note! As an alternative if a tool is not at hand, use two bolts M8 x 60 mm with heads cut off.

Note! Use a new seal.

Caution! Make sure that the component is correctly located on the locating dowels.

Caution! Make sure that the component is correctly located on the locating dowels.

Remove the Special Tool. [tool-symbol]

Install the screws. Tighten the bolts. Torque: M8 , 24 Nm

Install the marked component. Install the screw. Fasten the wiring harness using the existing clips. Torque: Position Sensor Connector, to ERAD housing , 10 Nm

Install 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)

Perform ERAD oil level check, refer to:

• Cleaning, Inspection and Adjustment
• 4 - Power transmission
• 46 - Rear axle, drive shafts
• 465 - final drive (front and rear)