2004 Volvo VN Service and Repair Manual

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Factory-Grade Data

2004 Volvo VN service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you troubleshoot accurately, follow step-by-step repair procedures, and reference wiring diagrams and system sections quickly while you work.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Wiring diagrams and electrical sections
  • Powertrain, brakes, steering, suspension, HVAC and more

Trims covered

  • VN42T Tractor Truck - Long Conventional

Engines covered

  • 12.1L 740Cu. In. 6 DIESEL

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2004 Volvo VN Recalls & Complaints

NHTSA #04V45700017/09/2004Component: VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR

ON CERTAIN TRUCKS EQUIPPED WITH VALEO WIPER SYSTEMS, THE WIPER MOTOR MAY BE SUSCEPTIVE TO SALT INTRUSION THAT COULD POSSIBLY LEAD TO A CONDITION WHERE THE CONNECTOR OVERHEATS TO A POINT WHERE THE CON

Consequence

IF THIS OCCURS, EXCESSIVE HEAT AND SMOKE COULD RESULT IN AN UNDER HOOD FIRE.

Remedy

DEALERS WILL INSPECT AND REPLACE THE CONNECTOR PLATE ON THE WINDSHIELD WIPER MOTOR. PHASE 2 OF THE

NHTSA #04V40500012/08/2004Component: POWER TRAIN:DRIVELINE:DRIVESHAFT

ON CERTAIN TRUCKS, THE BOLTS THAT RETAIN THE UNIVERSAL JOINT TO THE YOKE AT THE TRANSMISSION MAY NOT BE TIGHTENED CORRECTLY.

Consequence

THIS CAN RESULT IN THE DRIVE SHAFT COMING LOOSE FROM THE TRANSMISSION, INCREASING THE RISK OF A CRAS

Remedy

DEALERS WILL REMOVE AND INSTALL REMOVING NEW BOLTS, INSPECT FOR CROSS-THREADED BOLTS, AND REPLACE TH

NHTSA #04V31500002/07/2004Component: TRAILER HITCHES:FIFTH WHEEL ASSEMBLY

ON CERTAIN TRUCKS, A MALFUNCTION IN THE SOLENOID VALVE MAY ALLOW AIR TO BE RELEASED TO FIFTH WHEEL LATCH WHEN THE PARK BRAKE IS ENGAGED.

Consequence

THIS CONDITION COULD CAUSE THE FIFTH WHEEL LATCH TO RELEASE INADVERTENTLY WHEN THE PARK BRAKE IS ENG

Remedy

DEALERS WILL ADD AN ADDITIONAL SOLENOID VALVE IN SERIES WITH THE EXISTING PNEUMATIC CIRCUIT FOR THE

TSB #11030472

CBR - Z Spring Bracket Wear. Volvo Chassis

TSB #11021307

CBR - A significant GPS reporting issue is affecting fleet operations, with trucks maintaining back-office communication but failing to transmit GPS location data.

TSB #11000873

CBR - 11 Liter Engines - Fuel In Oil.

TSB #10241904

CBR: Volvo VHD & VN Models - Vehicle Wil Not Start, PTO Active Message Displayed In Cluster, PTO Light On When PTO Switch Is Turned Off

TSB #10241906

TSB: Barksdale Leveling Valve, Leak Test

TSB #10240244

CBR: Programming Failure - Chassis With Cummins Engine And An Allison Transmission

TSB #10235288

CBR: Volvo Chassis - Timing Gear Plate Repair. This solution provides supplementary information to be used when installing a Timing Gear Plate with Integrated Seal.

TSB #10235279

CBR: Volvo On-Highway Vehicles - Bendix ABS Fault SPN 807 FMI 13 Blink code 19-4. The new Central Pressure Control (CPC) system has changed the way that the ABS chuff test is performed.

Showing the 8 most recent of 111 technical service bulletins on file with NHTSA.

20050809Component: ELECTRICAL SYSTEM:WIRING:FUSES AND CIRCUIT BREAKERS

DT:HISTORY OF ELECTRICAL PROBLEMS SINCE PURCHASE OF SEMI-TRUCK. WHEN DRIVING AT ANY SPEEDS OR EVEN SHIFTING INTO GEAR THE TRUCK STOPS WITHOUT WARNING. WHEN THIS OCCURS THE ENGINE DIES AND LOSES ALL

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