Volvo RWD 444-544 Forum

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PV444 Idler Arm 444-544

After doing a lot of amateur restoration on my 444 I got it running but not "sorted" back in 2012. Then I put it aside and moved on to homebuilt airplanes. Now I have aged out of that and am working on getting the 444 truly road worthy. I found that the idler arm had some "play" and ordered new bushings, the spacer and the O rings.

Now I am trying to understand how it works. I looks to me like the bolt is intended to clamp the spacer in place and the bushings and arm are to pivot around the spacer. After taking it apart I find that the old spacer appears to be a perfect fit inside the old bushings. So I am thinking that back in the day I put it together wrong, and the spacer was not clamped, so the play I am seeing is between the bolt and spacer.

My problem is the the spacer length and arm thickness are virtually the same. I question that there is enough difference for me to clamp the spacer without binding on the arm. I could shim the end of the spacer somehow, or grind a little off the arm thickness to get it to clamp but I'm thinking there must be a better way.

Looking for suggestions. I am very humble about my skills and wondering what I am missing.








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    PV444 Idler Arm 444-544

    New bushings and the spacer should be fitted as a set. With the top and bottom bushings correctly fitted flush with the top of the arm the spacer should be just a fraction above them so that when the bolt is tightened they arm moves smoothly. Have you compared the lengths of the old and new spacers? The old one might have compressed over time. A machine shop should be able to make a new spacer that is a few thou too long that you can custom fit.
    From top - Through bolt/top bush/spacer/lower bush/washer/nut( use a good nyloc nut) Fit new dust rings and clean out the grease nipple. Lube well.
    There isn't much in the Green Book about this other than to ensure free movement. No torque setting for the nut.








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      PV444 Idler Arm 444-544

      Thanks for the quick reply. That is just how I understand it. I have measured the spacers old and new. They are within a thousandth of each other. The idler arm is just about that much thinner. I'll be seeing my mechanic mentor today and see what he suggests. I am thinking there will be a few minutes with a file and the idler arm in my future.








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        PV444 Idler Arm 444-544

        Resolved this by using a 26/1000 shim filed down to make shim O.D. a little less than spacer O.D. All solid now with no play.







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