TJ33358.5.1-2019

VOLVO CAR
SERVICE AND PARTS BUSINESS
Technical Journal
TITLE:
Replacement of ERAD components
REF NO:
ISSUING DEPARTMENT:
CAR MARKET:
TJ 33358.5.1
Technical Service
United States and Canada
PARTNER:
ISSUE DATE:
STATUS DATE:
3 US 7510 Volvo Car USA
2019-01-02
2019-01-10
FUNC GROUP:
FUNC DESC:
4600
Rear axle, drive shaft
Page 1 of 23
“Right first time in Time”
Attachment
File Name
PN 32240142.JPG
TJI-509127-1_1_2_en-US.pdf
File Size
0.1042 MB
6.1210 MB
Vehicle Type
Type
Eng
238
238
246
256
256
BC
BR
BR
BC
BR
Eng
Sales
Desc
B1BPHEV
B1FPHEV
B1FPHEV
B1BPHEV
B1FPHEV
Body
Gear
Steer
Model Year
2018-2018
2018-9999
2018-9999
2016-9999
2018-9999
Plant
Chassis range
-
Struc Week
Range
201718-201744
201746-209952
201717-209952
201526-209952
201717-209952
CSC Customer Symptom Codes
Code
YR
56
53
55
AJ
DL
8N
D2
Description
Drive mode "AWD"/Disengages automatically/Not available
Drive mode "OFF ROAD"/Disengages automatically/Not available
Driving, Twin Engine/Propulsion using electric motor not possible
Driving, Twin Engine/Propulsion using combustion engine/Always active/Active too often
Driving/Poor performance/lacks power
Warning lights and chimes/Malfunction Indicator Light ("Check engine" light) indication/no indication
Driving/Unusual noise/Unsure when/at all times
Front/rear axle/Unusual noise
Produced in the USA and available as an electronic document. Hard copy documents are printed in USA on recycled paper containing
a minimum of 50% wastepaper and 10% post-consumer waste.
© 2019 VOLVO CAR USA, LLC
Technical Journal 33358.5.1
VST Operation Number
VST Operation Number
98210-2
Description
ERAD transmission, replacement
DTC Diagnostic Trouble Codes
Control Module
IEM
IEM
Code
P286F00
P286D00
Fault Type
Intermittent
Intermittent
Rows beginning with * are modified
Note! If using a printed copy of this Technical Journal, first check for the latest online version.
Text
DESCRIPTION:
*Added note regarding substitutes for transmission mount
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.
Page 2 of 23
2019-01-10
Technical Journal 33358.5.1
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 attachments continue to next page. This TJ has two attachments.
2019-01-10
Page 3 of 23
Technical Journal 33358.5.1
Page 4 of 23
2019-01-10
Volvo Car Customer Service
Title
ERAD transmission
Action
Issue
1
TJ Instruction VCC-509127-1
Replacement
Date
2018-01
Model year
2018
2018
2016, 2017,
2018
Model
S90L
XC60 (18-)
XC90 (16-)
1 ( 19 )
Operation number:
98210-2
Reason
First issue
Affected vehicles
Engine
B4204T28, T35
B4204T28, T34, T35
B4204T28, T34, T35
Materials
Strip clamp
Description
Fixture
FLOOR STAND (TO FIXTURES)
Designation
Plastic mallet
Circlip pliers, internal
Page
Qty.
1.0
Part No.
999 7689
999 2520
Transmission
TG-81SC
TG-81SC
TG-81SC
Materials
Part No.
983750
Notes
Special tools
Notes
Substitute with an appropriate stand as necessary
Equipment
Part No.
TJ Instruction VCC-509127-1
Page 2 ( 19 )
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.
TJ Instruction VCC-509127-1
Page 3 ( 19 )
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.
TJ Instruction VCC-509127-1
Page 4 ( 19 )
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
TJ Instruction VCC-509127-1
Page 5 ( 19 )
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.
TJ Instruction VCC-509127-1
Page 6 ( 19 )
Remove the screw.
Lift the marked component up
Disconnect the connector.
Remove the marked part.
TJ Instruction VCC-509127-1
Page 7 ( 19 )
Fold marked part to one side.
Turn the engine
TJ Instruction VCC-509127-1
Page 8 ( 19 )
Remove the screws.
Note! Make sure that locating studs remains
in the timing gear casing.
Remove the marked part.
Use: Plastic mallet
TJ Instruction VCC-509127-1
Page 9 ( 19 )
Old sealing.
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.
TJ Instruction VCC-509127-1
Page 10 ( 19 )
Remove the marked part.
Use: Plastic mallet
Old sealing.
TJ Instruction VCC-509127-1
Page 11 ( 19 )
Release the lock.
Remove the marked part.
Use: Circlip pliers
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.
TJ Instruction VCC-509127-1
Page 12 ( 19 )
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
Note! As an alternative if a tool is not at
hand, use two bolts M8 x 60 mm with heads
cut off.
TJ Instruction VCC-509127-1
Page 13 ( 19 )
Note! Use a new seal.
Caution! Make sure that the component is
correctly located on the locating dowels.
TJ Instruction VCC-509127-1
Page 14 ( 19 )
Use: Strip clamp , 983750
Caution! Make sure that the wiring harness
does not catch.
Pull the wiring through.
TJ Instruction VCC-509127-1
Page 15 ( 19 )
Note! Make sure that the installation marks
are aligned.
Connect the connector.
TJ Instruction VCC-509127-1
Page 16 ( 19 )
Install the marked component.
Install the screw.
Torque:
Solenoid Connector, to ERAD housing ,
10 Nm
Note! Use a new seal.
TJ Instruction VCC-509127-1
Page 17 ( 19 )
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.
TJ Instruction VCC-509127-1
Page 18 ( 19 )
Remove the Special Tool.
Install the screws.
Tighten the bolts.
Torque:
M8 , 24 Nm
TJ Instruction VCC-509127-1
Page 19 ( 19 )
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)