VOLVO Service Bulletin Volvo Truck Corporation Sittog Sweden Trucks Date Group No. Release Page 102010 431 322 02 141) Gearbox, Disassembly-Inspection- Assembly (Gearbox removed) FHIFM AT2412D, AT(O)2612D, AT2812D, ATO3112D Gearbox, Disassembly-Inspection-Assembly 88995370 exo45100 EngishVolvo Truck Corporation Service Bulletin Date Group Release Page ro2010 431 322 02 a0 Service Procedures 43187-4 Gearbox, disassemble-inspect-assemble Gearbox removed Illustrations are used for several different variants: some details may therefore differ from the variant you are working on. The essential information in the illustrations is, however always correct. GXWARNING glasses. ‘Always it has necessity to use compressed air in some place of the gearbox, must wear the safety Special tools: 9986485, 9989876, 9990027, 9990028, 9990029, 9930037, 9990120, , 9992000, 9996081, 9992337, 9992613, 9992619, 9992671, 9996041, 9996042, 9996081, 9996176, 9996222, 9996239, 9996315, 9996479, 9996483, 9996876, 9996889, 9996905, 9996910, 9996917, 9996925, 9998051, 9998407, 9998542 9999696, 9999737, 86800005, 88800006, 88800075, 88600033, 88800034, 88800035, 9992003 Other special equipment 1159794, 1159795 Contents “Disassembly”, page 3 “inspection”, page 26. "Assembly", page 26.Volvo Truck Corporation Service Bulletin Date Group Release Page w2010 = 431 322 02 aan ® ® @ © Disassembly 1 Clean the outside of the gearhox Note: Plug nipples and valves during high pressure washing. 2 Connect a computer with the VCADS programinstalled, Use 40091-3 Gearbox activation, contro! housing {for removalifitting). In order for you to be able to remove the control housing, the splitter gear must be in its rear position, 2nd and 3rd in neutral and 1 streverse inthe rear posttion and set to the high range Goto step 14 if the VCADS program makes contact, with TECU. Otherwise go to the next step. 3 Note: I VCADS Pro cannot make contact with the ‘TECU the control housing must be manually moved to the correct position so that it can be lifted away from the gearbox. ‘The illustration shows the positions that the different air cylinders in the control housing must have in order for the control housing to be lifted away. In order for you to be able to remove the control housing, the splitter gear must be in its rear postion, 2nd and 3rd in neutral and ‘stireverse in the rear position and set to the high range.Volvo Truck Corporation Date Group No, Release Page Service Bulletin so2010 434 322 02 aay 4 Remove the screws holding the control housing on the geathox. Remove the screws holding the cover on the TECU. The figure shows the screw for the cover 5 Carefully ift the cover and disconnect the cable hamess between the cover and control housing, 6 Fit 4 screws (see figure). Tighten the screws so as not to damage the surface of the control housing. This ensures that the control housing cannot move and damage the pulse wheel on the main shaftVolvo Truck Corporation Date Group No Release «Page Service Bulletin ro210 431 322 02 se) 7 ‘The figure shows where the various air ducts are that are used to manually operate the control housing air cylinders. —o0 = t 5 Sa = Ate tf oS Fa Ss= op 8 Put the spliter gear in its rear position using a compressed air nozzle. If possible engage the forward position fist in order to check that the splitter gear moves correctly. TI ZO oDVolvo Truck Corporation Date Group No, Release Page Service Bulletin so2010 434 322 02 oaVolvo Truck Corporation Date Group No Release Page Service Bulletin ro210 431 322 02 7a, 9 Put the range gear in its forward position using a compressed air nozzle. If possible engage the rear position fist in order to check that the splitter gear moves correctly. 10 Check whether the gearbox is in neutral by turning the output shaft companion flange. Ift does, blow in the hole for reverse to engage the basic gearbox reverse gear. If not, go to the next step.Volvo Truck Corporation Service Bulletin Date Group Release Page w200 = 431 322 02 aan " It itis not possible to engage reverse gear, engage 2nd or 3rd gear. ‘The 2nd and 3rd gear air cylinder must be in neutral before reverse gear can be engaged. Note that there isa mechanical engagement interlock built into the control housing that makes it impossible to engage reverse unless 2nd or 3rd gear air cylinder is in neutral 2 Use a compressed air nozzle to put 2nd and 3rd gear air cylinders in neutral by carefully blowing into 2nd and 3rd gear holes while at the same time turning the output shaft companion flange a litle in order to better feel when neutral is engaged.Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 oa B Use a compressed air nozzle to engage the basic gearbox reverse gear. “ Remove the electrical connector for the clutch valve assembly in the control housing 5 Remove the pneumatic connection to the valve assembly, and remove the three screws securing the valve assembly.Volvo Truck Corporation Service Bulletin Date Group No. Release Page w200 = 431 322 02 1049 6 Remove the electrical connection for the clutch position sensor on the valve assembly. Remave the valve assembly. "7 Fit the spacer flange onto the fixing plate. With the aid of the arm, fit the fixing plate to the gearbox. Secure the gearbox into the unit stand. 9986486, 9990031, 9996905, 9999737 8 Drain the gearbox oil QXWARNING Hot oil can cause burns. Use protective gloves.Volvo Truck Corporation Date Group No Release Page Service Bulletin ro210 431 322 02 ney 19 Remove the oil fer drain plug. Refit the drain plug after the oll has finished draining, 20 Remove the oil filter cover and guide sleeve Note: There will be a little oll left in the cover. 2 Remove the oilfiter housing and where applicable the all cooler.Volvo Truck Corporation Date Group Release Page Service Bulletin w200 = 431 322 02 249 2 Remove the control housing. If necessary, carefully Use a crowbar to loosen the control housing from its guide pins. 9992337, 9992337 23 Ifthe gearbox is equipped with a retarder, perform step 24-26. Otherwise go to step 27. 24 Lt Remove the retarder’s temperature sensor trom the =| heat exchanger or aternatively, remove the connector from the plate 25 Remove the retarder wiring cable ties.Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 ey 26 Remove the three screws securing the heat exchanger and retarder cooler. a Turn the gearbox so that the output shaft flange faces upwards. 9998570, 28 Fit counterhold 9998670. Remove the companion flange nut and O-ring, 9998570,Volvo Truck Corporation Date Group No. Relesse Page Service Bulletin v2 ©6434 322s 1489 29 Remove the companion flange. 9990084, 9992619, 9992671, 9996166, 9996222, 9998607 30 Remove the plug, spring and blocking body for the range function. If necessary use a magnet to pull out the blocking body. 34 Ifthe gearbox is equipped with a retarder, perform step 32-33. Otherwise go to step 34.Volvo Truck Corporation Service Bulletin Date Group Release Page w2010 = 431 322 02 189 32 Remove the four nuts securing the retarder to the range housing (A, 8, C and D in the illustration) 33 Carefully ift the retarder away from the gearbox. 34 Remove the range housing securing screws. Note: If the gearbox has a retarder, do not forget to remove the screws from the retarder socket. 35 Fit the adapter and lifting eye into the output shaft. 9996479, 9996925Volvo Truck Corporation Service Bulletin Date Group Release Page w200 = 431 322 02 1049 9998051 9990027 36 Spit the main housing and range housing. Use press tool go9805t a Lift the range housing away carefully. Note: Ensure that the range cylinder piston rod does not jam in the gearbox housing, the shaft may then be damaged. 38 Remove the oil distributor pipe. Use a socket 9990027 39 Remove the circlip securing the high range synchronizer.Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 rey 40 Remove both halves of the washer. a“ Fit both the puller halves on to the high range synchronizer hub. 38800015 42 Fit one haf of the puller 9998542 on to the puller rings, together with the hydraulic cylinder, spindle and drift. Note: Ensure that the spit in the puller rings is at 90° to the split in the puller. 88800015, 9992619, 9992671, 9996889, 9998542 43 Fitthe other half of the puller 9998542. Fit the hydraulic ump. Press off the high range synchronizer. 9996222Volvo Truck Corporation Date Group No, Release Page Service Bulletin so2010 434 322 02 1849 44 Remove the reversing shaft centre screw. 45 Remove the rear cover and adjustment washer for the countershatt 46 Fit the puller and spindle to the reversing shaft 9996316, 9996917 a7 Fit the hollow drift, hydraulic cylinder and hydraulic, ump to the spindle. 9992671 9990120, 9992671, 9996222 9990120 48 Press out the reversing shaftVolvo Truck Corporation Service Bulletin Date Group Release Page w2010 = 431 322 02 te iy = Se ; p) 49 Remove the oil pump with the reverse gear pinion. 50 Remove the rear cover far the main shaft and where applicable the oil pipe for the overdrive gear. st Remove the adjustment shim for the main shatt 52 ‘Tum the gearbox so that the input shaft (the shaft with discs) faces upwards,Volvo Truck Corporation Service Bulletin Date Group Release Page w200 = 431 322 02 2009 53 Remove the clip securing the air hose in the clutch cylinder. Carefully remove the clamps for the electrical cable and the air hose to the clutch cylinder. Remove the three cluteh cylinder screws. 54 Remove the air hose for the clutch cylinder and the air pipe for the countershatt brake.Volvo Truck Corporation Service Bulletin Date Group No. Release Page, w2010 = 431 322 02 214 55 Remove the countershaft brake. 56 Remove the piston A and spring B for the countershaft brake, oT Remove the cluteh housing,Volvo Truck Corporation Service Bulletin Date Group Release Page w200 = 431 322 02 Zan 9996910 58 Remove the air pipe nipple for the countershaft brake Pipe. 59 Remove the sleeve from the intermediate shat 60 Remove the magnet located between the clutch housing and the lower part of the base housing. Clean the magnet 61 Prepare the lifting tool as illustrated. Use the two lifting arms and the spacer ring from special tool 9990028, lifting arm kit 88800006, fixture plate and chain. Fit the lifting tool into the shaft assembly. 88800006, 9990028, 9996239, a9g6910Volvo Truck Corporation Date Group No. Release Page Service Bulletin ro200 = 431 322 02 230 62 Make a wooden fixture as illustrated to recelve the shaft package Note: The main shaft must not be placed on a ‘workbench or similar. This can damage the gear teeth. Therefore all work must be carried out with the main shaft upright. 63 Carefully it out the shaft assembly and place it in the ‘wooden fixture. 64Volvo Truck Corporation Date Group No, Release Page Service Bulletin so2010 434 322 02 24a) Remove the lifting tool from the shaft assembly. 65 9996041 Pull the countershaft outer race out of the clutch housing. Use a puller, yoke, cylinder, pump and spindle. Note: Only remove the outer race if the bearing will be changed 88800033, 88800036, 9992671, 9996041, 9996222 66 roo Pull the input shaft outer race out of the clutch housing. Use a puller, yoke, cylinder, pump and spindle. Note: Only remove the outer race if the bearing will ensognse 9992671 be changed 9996222 88800033, 88800034, 9992671, 9996041, 9996222Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 25a) or Drive the outer race of the countershaft rear bearing ut of the gearbox housing. Use a drift and handle. Note: Only remove the outer race if the bearing will be changed. ‘A= 9992000 B= 9996081 9992000, 9996081 68 Drive the outer race of the main shaft rear bearing ut of the gearbox housing. Use a drift and handle. Note: Only remove the outer race if the bearing will be changed 9992613, 9996176 69 Remove the oll screen and the overflow vawveVolvo Truck Corporation Service Bulletin Date Group Release Page w200 = 431 322 02 2009) Inspection 70 Clean all parts. Check bearings, shafts, gears and synchronizers for damage and wear. Replace damaged or worn parts, Z\ CAUTION New bearings and bearing races must be taken from the same box. ” Lubricate all parts with gearbox oil before installation. Assembly 2 Drive the outer race of the main shaft rear bearing into the housing until the outer race is about 5 mm above the bottom of the gearbox housing. Do the same thing for the outer race for the countershaft Ifthe outer races have not been removed, they should be tapped out so that they are about 5mm above the bottom of the gearbox housing. Note: This step must be performed to ensure that the measurements of the shaft assembly wil be correct. 3 ‘Tum the gearbox over 1/2 turn. Fit the oil screen and overflow valve. Torque tighten the valve. 4525Nm 1189794Volvo Truck Corporation Service Bulletin Date Group Release Page w2010 = 431 322 02 zea 74 Assemble the shaft assembly. Secure the lifting tool to. the shaft assembly. Lubricate all bearings. Note: It is important that the bearings are alled, to give the correct clearances, 88800006, 9990028, 9996239, 9996910 75 Carefully lit the shaft assembly into the gearbox housing, 76 Remove the fixture and the three lifting arms from the shafts. 7 Install the nipple for the air pipe for the countershatt brake,Volvo Truck Corporation Service Bulletin Date Group Release Page w200 = 431 322 02 2009 78 When changing the countershaft outer race in the clutch housing, press it in so that it bottoms in the clutch housing. Use a cylinder, dri, hollow drift and spindle 9992003, 9996041, 9996042, 9992671, 9996222 79 When changing the input shaft outer race in the clutch housing, press it in so that it bottoms in the clutch housing. Use a cylinder, pump, drift, hollow drift and spindle. 9992671, 9996041, 9996042, 9996081, 9996222, 9998401 9996042 80 Apply VOLVO approved high-temperature quid gasket fo the main housing’s mating surfaces to the clutch housing according to the ilustration. Fit the magnet,Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 Pea) a Put the clutch housing on the base housing. Make sure that the guide dowels enter their holes in the clutch housing, 82 Install the clutch housing screws and torque tighten them alternately. 110 10Nm 1189795 83 Remove the seal for the input shaft. Use a lever. Note: Replace the seal if necessary 9992337 a4 Press in the seal with a dri. Note: Fill the space between the seal lips to 1/3 with aVOLVO approved grease. Avoid getting grease on the felt ring. Oil in the sealing ring mating face to the input shaft before assembly. 38800008 85 Tum the gearbox 1/2 tunVolvo Truck Corporation Date Group No, Release Page Service Bulletin ro2010 = 431 322 02 308) 86 When measuring the main shaft and countershaft the 2 LS gear must be engaged. fit screw 9996917 onto the main shaft and screw 9996483 on the countershaft, Without overdrive: The splitter gear clutch ring in its forward position, With overdrive: The splitter gear coupling cone in itsrearmost position Note: The countershaft brake and oil pump must not be installed a7 Install a shim which is 0,9 mm thinner than the original shim on the mainshaft 38 Lubricate the sealing ring and install the rear cover. Torque tighten diagonally, 4025 Nm 89 Install the countershatt cover, with a shim. The shim should be 0,9 mm thinner than the original shim, Fit the screws and torque tighten them diagonally 4025 Nm 90 When measuring the mainshaft and countershatt, gear 2 LS shall be engaged. Without overdrive: The splitter gear clutch ring in its frontmost position With overdrive: The splitter gear clutch ring in itsrearmost position Note: The countershaft brake must not be engagedVolvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 ana 1 Lock the gears with the holder for the clutch sleeves. 9990029, 92 9996917 9996483 Fit screw 9996917 on the main shaft and screw 9996483 on the countershatt. 9996917, 9996483 93 Rotate the shafts 20 turns 94 Attach the dial gauge to the magnetic stand. The tip of the dial gauge should touch the sun wheel. Zero the dial gauge and mark up the measurement point 9989876, 9999696Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro2010 = 431 322 02 se 95 Turn the gearbox 1/2 turn. Lift the measuring probe and tum the shaft 20 tums, read off the backlash at the marked posttion and note tt 96 Tur the gearbox 1/2 tun. Remove the main shaft cover, Place a shim that is between 0.1 and 0.2 mm. thicker than the measured play together with the existing shim, This gives a preload of between 0.1 and 0.2 mm, Install the mainshaft cover. Note: Torque tighten the screws diagonally. 4025 Nm 7 Rotate the shafts 20 turns, 98 Turn the dial gauge to the countershaft. The tip of the dial gauge should touch the countershaft. Zero the dial gauge and mark up the measurement point. 99 Tum the gearbox over 1/2 turn 100 Lift the tip of the dial gauge and rotate the countershaft at least 20 tums, Read off the clearance from the marked measurement point and note the value. 101 ‘Tum the gearbox 1/2 tum. Remove the countershaft cover, Place a shim that is between 0.1 and 0.2 mm. thicker than the measured play together with the existing shim, This gives a preload of between 0.1 and 0.2 mm, Install the countershaft cover. Note: Torque tighten the screws diagonally. 4025 NmVolvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 saan) 102 9996017 Remove * Dial indicator 9989876 * Magnetic stand 9999696 * Bolt 9996917 * Bolt 9996483 9989876, 9959696, 9996917, 9996483 103 Remove the counter shaft cover. 104 Fit a new gasket on the oil pump. 105 Install the oil pump. Hammer the reversing shaft into the gearbox housing using a plastic mallet. Fit the ‘screws into the reversing gear and torque tighten. Note: Make sure that the bevel for the rotation lock isin the correct position. 48:8 Nm 1189794 106 Install the counter shaft cover. Fit the screws and tighten them diagonally. 4025 Nm 1189794Volvo Truck Corporation Date Group No, Release Page Service Bulletin so2010 434 322 02 aaa) 107 Where applicable fit the overdrive oll pipe. 108 Press in the synchronizer for high range 88800015, 9992671, 9996081, 9996222, 9996316, g998642 109 Fit both the washer halves. 10 Fit the high range circlip.Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 354) m1 Remove the forks 9990029 holding the clutch sleeves: in place 9990029, 12 i and fit new O-rings. instal the oil distribution piping, Torque tighten the oil distribution piping. Use a socket. 9990027 250 + 35 Nm 1189795 13 Apply VOLVO approved high-temperature liquid gasket. 14 Fit the adapter and lifting eye into the range section output shaft. Position the range housing over the main housing. Lower and line up the piston rod and planet wheel, Secure the range housing. Torque tighten the bolts, Note: Insert the guide pins 9996876 into the gearbox housing to facilitate the assembly. 9996479, 9996876, 9996925 110 + 10Nm. 1189795Volvo Truck Corporation Service Bulletin Date Group Release Page w200 = 431 322 02 3009) pe HU | HU 15 If the gearbox is equipped with a retarder, perform steps 116-121. Otherwise go to step 122. 16 Fit the retarder with a new O-ring, greased with silicon grease. Guide the bolts into the holes and lower the retarder into position. Fit the nuts and tighten them by hand as illustrated in the order A, B, C and finally D. Torque tighten the nuts in the same order. ‘Then angle-tighten the nuts 45° in the same order. ‘Then angle-tighten the nuts another 45° in the same order. Note: After the retarder has been tightened, there should be a gap between the retarder and the range housing, 30 Nmai 4189794 "7 Tur the gearbox 1/4 tum. 18 Install new O-rings on the heat exchanger and the Tange housing. Apply silicon grease to the O-rings. 19 Lift up the heat exchanger so that the narrow parts are guided into their respective holes. Fit the securing bolts. Pull the heat exchanger in with the upper rear screws. Torque tighten the bolts, 85Nm 1189795 120 Fit the temperature sensor for the retarder.Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro210 431 322 02 ave 121 Clamp the retarder wiring 122 Install the blocking body, spring and plug for the range: ) function. 123 Install the oil fter housing with a new seal and a new oil fiter. Where applicable, fit the oil cooler. Torque tighten the botts. 2023Nm 1189794 128 Tum the gearbox 1/4 tunVolvo Truck Corporation Date Group No. Relesse Page Service Bulletin ro2010 = 431 322 02 308) 125 Fit a new gasket between the brake and the clutch housing 126 Add the discs alternately. Begin and end with a steel disc (two friction discs and three steel discs) 12 Fit the sleeve with a new O-ring, spring and piston,Volvo Truck Corporation Service Bulletin Date Group Release Page w2010 = 431 322 02 3) 128 Fit the cylinder over the disc assembly and torque tighten the screws, 4525Nm 1189794 129 Clean the nipple threads. Fit the brake pipe. Screw the nuts fully on by hand. Then tighten wth a socket spanner a further 3/4 turn, 130 Fit the clutch cylinder and air hose. Secure the hose with a clip. Torque tighten the bots. 4525Nm 1189794 131 Tum the gearbox 1/4 tun 132 Fit the magnetic stand and dial gauge on the holder. Check the runout in the gear wheel. The measuring tip of the dial gauge must be 2. mm below the teeth. The ‘maximum permitted runout is 0.4 mm. 9999696, 9989876, 9990029Volvo Truck Corporation Date Group No, Release Page Service Bulletin ro2010 = 431 322 02 an 133 Fit a new seal to the control housing. 134 Insert the dowels into the gearbox housing, 9996876 g096876 135 Ensure that the splitter gear clutch ring is in its rearmost postion, the 2nd/3rd gear clutch ring is in neutral, the ‘stireverse clutch ring is in its rear position and the Tange gear is set to high range (with the range shaft in its forward position and the piston in the range cylinder in its innermost position) and that the shift forks in the control housing are matched to the clutch rings, This is to enable the control housing to be fitted. 136 Carefully lower the control housing so that no gear teeth are damaged. It is important for the clutch fork for the splitter gear to enter the clutch ring correctly, Carefully tap the control housing down at the guide pins. 137 Remove the guide pins. 138 Install the contro! housing screws and torque tighten them diagonally. 110 = 10Nm 1189795Volvo Truck Corporation Date Group No Release Page Service Bulletin wo200 = 434 322 02 aay 139 Connect VCADS, calibrate the gearbox and select, perform test to check that the gearbox is working properly 140 Remove the gearbox from the overhaul stand 41 Remove the fixture from the gearbox. Install the valve assembly. Clamp the air hose and electrical wiring