Gearbox, Disassembly-Inspection-Assembly (Gearbox Removed)

Service BulletinVolvo Truck CorporationGteborg, Sweden Trucks

Date Group No. Release Page

10.2010 431 322 02 1(41)

Gearbox, Disassembly-Inspection-Assembly

(Gearbox removed)

FH/FM

AT2412D, AT(O)2612D, AT2812D,ATO3112D

Gearbox, Disassembly-Inspection-Assembly

T4021207

88995370ENG45100 English

Volvo Truck Corporation Date Group No. Release PageService Bulletin 10.2010 431 322 02 2(41)

Service Procedures

43187-4Gearbox, disassemble-inspect-assemble

Gearbox removedIllustrations are used for several different variants: some details may therefore differfrom the variant you are working on. The essential information in the illustrations ishowever always correct.

WARNING

Always it has necessity to use compressed air insome place of the gearbox, must wear the safetyglasses.

Special tools: 9986485, 9989876, 9990027,9990028, 9990029, 9990031, 9990120, ,9992000, 9996081, 9992337, 9992613,9992619 , 9992671, 9996041, 9996042,9996081, 9996176, 9996222, 9996239,9996315, 9996479, 9996483, 9996876,9996889, 9996905, 9996910, 9996917,9996925, 9998051, 9998401, 9998542,9999696, 9999737, 88800005, 88800006,88800015, 88800033, 88800034,88800035, 9992003

Other special equipment 1159794, 1159795

ContentsDisassembly, page 3 .

Inspection, page 26.

Assembly, page 26.


Disassembly1

1Clean the outside of the gearbox.

Note: Plug nipples and valves during high pressurewashing.

2

T4021646

2Connect a computer with the VCADS program installed.Use 40091-3 Gearbox activation, control housing(for removal/fitting). In order for you to be able toremove the control housing, the splitter gear must be inits rear position, 2nd and 3rd in neutral and 1st/reversein the rear position and set to the high range.Go to step 14 if the VCADS program makes contactwith TECU. Otherwise go to the next step.

3

T4021646

3

Note: If VCADS Pro cannot make contact with theTECU the control housing must be manually moved tothe correct position so that it can be lifted away fromthe gearbox.

The illustration shows the positions that the different aircylinders in the control housing must have in order forthe control housing to be lifted away.In order for you to be able to remove the controlhousing, the splitter gear must be in its rear position,2nd and 3rd in neutral and 1st/reverse in the rearposition and set to the high range.


4

T4022582

4Remove the screws holding the control housing on thegearbox. Remove the screws holding the cover on theTECU. The figure shows the screw for the cover.

5

T4020597

5Carefully lift the cover and disconnect the cableharness between the cover and control housing.

6

T4022631

6Fit 4 screws (see figure). Tighten the screws so as notto damage the surface of the control housing. Thisensures that the control housing cannot move anddamage the pulse wheel on the main shaft.


7

T4023202

DD

T4023201

OD

7The figure shows where the various air ducts are thatare used to manually operate the control housing aircylinders.

8

T4022534

DD

8Put the splitter gear in its rear position using acompressed air nozzle. If possible engage the forwardposition first in order to check that the splitter gearmoves correctly.


T4022533

OD

T4022535


9

T4022531

T4022532

9Put the range gear in its forward position using acompressed air nozzle. If possible engage the rearposition first in order to check that the splitter gearmoves correctly.

10

T4023203

10Check whether the gearbox is in neutral by turning theoutput shaft companion flange. If it does, blow in thehole for reverse to engage the basic gearbox reversegear. If not, go to the next step.


11

T4022583

11

If it is not possible to engage reverse gear, engage 2ndor 3rd gear.

The 2nd and 3rd gear air cylinder must be in neutralbefore reverse gear can be engaged. Note that thereis a mechanical engagement interlock built into thecontrol housing that makes it impossible to engagereverse unless 2nd or 3rd gear air cylinder is in neutral.

12

T4022537

T4022538

12Use a compressed air nozzle to put 2nd and 3rd gearair cylinders in neutral by carefully blowing into 2ndand 3rd gear holes while at the same time turning theoutput shaft companion flange a little in order to betterfeel when neutral is engaged.


13

T4023203

13Use a compressed air nozzle to engage the basicgearbox reverse gear.

14

T4020995

14Remove the electrical connector for the clutch valveassembly in the control housing.

15

T4020994

15Remove the pneumatic connection to the valveassembly, and remove the three screws securing thevalve assembly.


16

T4020996

16Remove the electrical connection for the clutch positionsensor on the valve assembly. Remove the valveassembly.

17

T4020968

17Fit the spacer flange onto the fixing plate. With the aidof the arm, fit the fixing plate to the gearbox. Securethe gearbox into the unit stand.

9986485, 9990031, 9996905, 9999737

18

T4022639

18Drain the gearbox oil.

WARNING

Hot oil can cause burns. Use protective gloves.


19

T4020962

19Remove the oil filter drain plug. Refit the drain plugafter the oil has finished draining.

20

T4020963

20Remove the oil filter cover and guide sleeve.

Note: There will be a little oil left in the cover.

21

T4020964

21Remove the oil filter housing and where applicable theoil cooler.


22

T4018975

22Remove the control housing. If necessary, carefullyuse a crowbar to loosen the control housing from itsguide pins.

9992337

2323If the gearbox is equipped with a retarder, perform step24 26. Otherwise go to step 27.

24

T4020965

24Remove the retarders temperature sensor from theheat exchanger or alternatively, remove the connectorfrom the plate.

25

T4020966

25Remove the retarder wiring cable ties.


26

T4020967

26Remove the three screws securing the heat exchangerand retarder cooler.

2727Turn the gearbox so that the output shaft flange facesupwards.

28

T4021488

28Fit counterhold 9998570.Remove the companion flange nut and O-ring.

9998570


29

T4022460

29Remove the companion flange.

9990084, 9992619, 9992671, 9996156, 9996222,9998597

30

C4052785

30Remove the plug, spring and blocking body for therange function. If necessary use a magnet to pull outthe blocking body.

3131If the gearbox is equipped with a retarder, perform step32 33. Otherwise go to step 34.


32

T5012262

32Remove the four nuts securing the retarder to the rangehousing (A, B, C and D in the illustration).

3333Carefully lift the retarder away from the gearbox.

34

T4023008

34Remove the range housing securing screws.

Note: If the gearbox has a retarder, do not forget toremove the screws from the retarder socket.

35

T4023007

35Fit the adapter and lifting eye into the output shaft.

9996479, 9996925


36

T4023009

36Split the main housing and range housing. Use presstool.

9998051

3737Lift the range housing away carefully.

Note: Ensure that the range cylinder piston rod doesnot jam in the gearbox housing, the shaft may then bedamaged.

38

T4021428

38Remove the oil distributor pipe. Use a socket.

9990027

39

T4021426

39Remove the circlip securing the high rangesynchronizer.


40

T4021427

40Remove both halves of the washer.

41

T4021425

41Fit both the puller halves on to the high rangesynchronizer hub.

88800015

42

T4021429

42Fit one half of the puller 9998542 on to the puller rings,together with the hydraulic cylinder, spindle and drift.

Note: Ensure that the split in the puller rings is at 90to the split in the puller.

88800015, 9992619, 9992671, 9996889, 9998542

43

T4021430

43Fit the other half of the puller 9998542. Fit the hydraulicpump. Press off the high range synchronizer.

9996222


44

T4021431

44Remove the reversing shaft centre screw.

4545Remove the rear cover and adjustment washer for thecountershaft.

46

T4021432

46Fit the puller and spindle to the reversing shaft.

9996315, 9996917

47

T4021433

47Fit the hollow drift, hydraulic cylinder and hydraulicpump to the spindle.

9990120, 9992671, 9996222

4848Press out the reversing shaft.


49

T4020987

49Remove the oil pump with the reverse gear pinion.

50

T4021434

50Remove the rear cover for the main shaft and whereapplicable the oil pipe for the overdrive gear.

51

T4021435

51Remove the adjustment shim for the main shaft.

5252Turn the gearbox so that the input shaft (the shaft withdiscs) faces upwards.


53

T4020990

53Remove the clip securing the air hose in the clutchcylinder. Carefully remove the clamps for the electricalcable and the air hose to the clutch cylinder. Removethe three clutch cylinder screws.

54

T4020991

54Remove the air hose for the clutch cylinder and the airpipe for the countershaft brake.


55

T4020992

55Remove the countershaft brake.

56

T4020993

56Remove the piston A and spring B for the countershaftbrake.

5757Remove the clutch housing.


58

T4019239

58Remove the air pipe nipple for the countershaft brakepipe.

59

T4019240

59Remove the sleeve from the intermediate shaft.

6060Remove the magnet located between the clutchhousing and the lower part of the base housing. Cleanthe magnet.

61

T4021049

61Prepare the lifting tool as illustrated. Use the two liftingarms and the spacer ring from special tool 9990028,lifting arm kit 88800006, fixture plate and chain. Fit thelifting tool into the shaft assembly.

88800006, 9990028, 9996239, 9996910


62

T4021768

62Make a wooden fixture as illustrated to receive the shaftpackage.

Note: The main shaft must not be placed on aworkbench or similar. This can damage the gear teeth.Therefore all work must be carried out with the mainshaft upright.

63

T4021767

63Carefully lift out the shaft assembly and place it in thewooden fixture.

6464


Remove the lifting tool from the shaft assembly.

65

T4021545

65Pull the countershaft outer race out of the clutchhousing. Use a puller, yoke, cylinder, pump and spindle.

Note: Only remove the outer race if the bearing willbe changed.

88800033, 88800035, 9992671, 9996041, 9996222

66

T4021544

66Pull the input shaft outer race out of the clutchhousing. Use a puller, yoke, cylinder, pump and spindle.


88800033, 88800034, 9992671, 9996041, 9996222


67

C4060678

67Drive the outer race of the countershaft rear bearingout of the gearbox housing. Use a drift and handle.


A = 9992000B = 9996081

9992000, 9996081

68

T4019212

68Drive the outer race of the main shaft rear bearingout of the gearbox housing. Use a drift and handle.


9992613, 9996176

69

T4021270

69Remove the oil screen and the overflow valve.


Inspection70

70Clean all parts. Check bearings, shafts, gears andsynchronizers for damage and wear. Replace damagedor worn parts.

CAUTION

New bearings and bearing races must be taken fromthe same box.

7171Lubricate all parts with gearbox oil before installation.

Assembly72

T4021804

72Drive the outer race of the main shaft rear bearinginto the housing until the outer race is about 5 mmabove the bottom of the gearbox housing. Do the samething for the outer race for the countershaft.If the outer races have not been removed, they shouldbe tapped out so that they are about 5 mm above thebottom of the gearbox housing.

Note: This step must be performed to ensure that themeasurements of the shaft assembly will be correct.

73

T4021270

73Turn the gearbox over 1/2 turn. Fit the oil screen andoverflow valve. Torque tighten the valve.

45 5 Nm1159794


74

T4021049

74Assemble the shaft assembly. Secure the lifting tool tothe shaft assembly. Lubricate all bearings.

Note: It is important that the bearings are oiled, to givethe correct clearances.

88800006, 9990028, 9996239, 9996910

7575Carefully lift the shaft assembly into the gearboxhousing.

7676Remove the fixture and the three lifting arms from theshafts.

77

T4019239

77Install the nipple for the air pipe for the countershaftbrake.


78

T4021542

78When changing the countershaft outer race in theclutch housing, press it in so that it bottoms in the clutchhousing. Use a cylinder, drift, hollow drift and spindle.

9992003, 9996041, 9996042, 9992671, 9996222

79

T4021543

79When changing the input shaft outer race in theclutch housing, press it in so that it bottoms in theclutch housing. Use a cylinder, pump, drift, hollow driftand spindle.

9992671, 9996041, 9996042, 9996081, 9996222,9998401

80

T4019215

80Apply VOLVO approved high-temperature liquidgasket to the main housings mating surfaces to theclutch housing according to the illustration. Fit themagnet.


8181Put the clutch housing on the base housing. Make surethat the guide dowels enter their holes in the clutchhousing.

8282Install the clutch housing screws and torque tightenthem alternately.

110 10Nm1159795

83

T4021445

83Remove the seal for the input shaft. Use a lever.

Note: Replace the seal if necessary.

9992337

84

T4021446

84Press in the seal with a drift.

Note: Fill the space between the seal lips to 1/3 witha VOLVO approved grease. Avoid getting grease onthe felt ring. Oil in the sealing ring mating face to theinput shaft before assembly.

88800005

8585Turn the gearbox 1/2 turn.


8686When measuring the main shaft and countershaft the 2LS gear must be engaged. fit screw 9996917 on to themain shaft and screw 9996483 on the countershaft.Without overdrive: The splitter gear clutch ring in itsforward position.With overdrive: The splitter gear coupling cone initsrearmost position.

Note: The countershaft brake and oil pump must notbe installed.

87

T4021435

87Install a shim which is 0,9 mm thinner than the originalshim on the mainshaft.

88

T4021434

88Lubricate the sealing ring and install the rear cover.Torque tighten diagonally.

405 Nm

8989Install the countershaft cover, with a shim. The shimshould be 0,9 mm thinner than the original shim. Fit thescrews and torque tighten them diagonally.

405 Nm

9090When measuring the mainshaft and countershaft, gear2 LS shall be engaged.Without overdrive: The splitter gear clutch ring in itsfrontmost position.With overdrive: The splitter gear clutch ring initsrearmost position.

Note: The countershaft brake must not be engaged.


91

T4019217

91Lock the gears with the holder for the clutch sleeves.

9990029

92

T4021483

92Fit screw 9996917 on the main shaft and screw9996483 on the countershaft.

9996917, 9996483

93

T4021484

93Rotate the shafts 20 turns.

94

T4021485

94Attach the dial gauge to the magnetic stand. The tip ofthe dial gauge should touch the sun wheel. Zero thedial gauge and mark up the measurement point.

9989876, 9999696


9595Turn the gearbox 1/2 turn. Lift the measuring probeand turn the shaft 20 turns, read off the backlash at themarked position and note it.

9696Turn the gearbox 1/2 turn. Remove the main shaftcover. Place a shim that is between 0.1 and 0.2 mmthicker than the measured play together with theexisting shim.This gives a preload of between 0.1 and 0.2 mm.Install the mainshaft cover.

Note: Torque tighten the screws diagonally.

405 Nm

9797Rotate the shafts 20 turns.

98

T4021486

98Turn the dial gauge to the countershaft. The tip of thedial gauge should touch the countershaft. Zero the dialgauge and mark up the measurement point.

9999Turn the gearbox over 1/2 turn.

100100Lift the tip of the dial gauge and rotate the countershaftat least 20 turns. Read off the clearance from themarked measurement point and note the value.

101101Turn the gearbox 1/2 turn. Remove the countershaftcover. Place a shim that is between 0.1 and 0.2 mmthicker than the measured play together with theexisting shim.This gives a preload of between 0.1 and 0.2 mm.Install the countershaft cover.

Note: Torque tighten the screws diagonally.

405 Nm


102

T4021483

102Remove

Dial indicator 9989876 Magnetic stand 9999696 Bolt 9996917 Bolt 9996483

9989876, 9999696, 9996917, 9996483

103103Remove the counter shaft cover.

104

T4021482

104Fit a new gasket on the oil pump.

105

T4020987

105Install the oil pump. Hammer the reversing shaft intothe gearbox housing using a plastic mallet. Fit thescrews into the reversing gear and torque tighten.

Note: Make sure that the bevel for the rotation lockis in the correct position.

488 Nm1159794

106106Install the counter shaft cover. Fit the screws andtighten them diagonally.

405 Nm1159794


107107Where applicable fit the overdrive oil pipe.

108

T4022457

108Press in the synchronizer for high range.

88800015, 9992671, 9996081, 9996222, 9996315,9998542

109

T4021427

109Fit both the washer halves.

110

T4021426

110Fit the high range circlip.


111

T4019217

111Remove the forks 9990029 holding the clutch sleevesin place.

9990029

112

T4021428

112Oil and fit new O-rings. Install the oil distribution piping.Torque tighten the oil distribution piping. Use a socket.

9990027250 35 Nm1159795

113

T4023186

113Apply VOLVO approved high-temperature liquidgasket.

114

T4023007

114Fit the adapter and lifting eye into the range sectionoutput shaft. Position the range housing over the mainhousing. Lower and line up the piston rod and planetwheel. Secure the range housing. Torque tighten thebolts.

Note: Insert the guide pins 9996876 into the gearboxhousing to facilitate the assembly.

9996479, 9996876, 9996925110 10Nm1159795


115115If the gearbox is equipped with a retarder, performsteps 116 121. Otherwise go to step 122.

116

T5012262

116

Fit the retarder with a new O-ring, greased with silicongrease. Guide the bolts into the holes and lower theretarder into position. Fit the nuts and tighten them byhand 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 sameorder.

Note: After the retarder has been tightened, thereshould be a gap between the retarder and the rangehousing.

30 Nm451159794


118118Install new O-rings on the heat exchanger and therange housing. Apply silicon grease to the O-rings.

119

T4020967

119Lift up the heat exchanger so that the narrow partsare guided into their respective holes. Fit the securingbolts. Pull the heat exchanger in with the upper rearscrews. Torque tighten the bolts.

85 Nm1159795

120

T4020965

120Fit the temperature sensor for the retarder.


121

T4020966

121Clamp the retarder wiring.

122

C4052785

122Install the blocking body, spring and plug for the rangefunction.

123

T4020964

123Install the oil filter housing with a new seal and a newoil filter. Where applicable, fit the oil cooler. Torquetighten the bolts.

20 3Nm1159794



125

T4019225

125Fit a new gasket between the brake and the clutchhousing.

126

T4019226

126Add the discs alternately. Begin and end with a steeldisc (two friction discs and three steel discs).

127

T4019286

127Fit the sleeve with a new O-ring, spring and piston.


128

T4020992

128Fit the cylinder over the disc assembly and torquetighten the screws.

45 5 Nm1159794

129129Clean the nipple threads. Fit the brake pipe. Screwthe nuts fully on by hand. Then tighten with a socketspanner a further 3/4 turn.

130130Fit the clutch cylinder and air hose. Secure the hosewith a clip. Torque tighten the bolts.

45 5 Nm1159794


132

T4019229

132Fit the magnetic stand and dial gauge on the holder.Check the runout in the gear wheel. The measuring tipof the dial gauge must be 2 mm below the teeth. Themaximum permitted runout is 0.4 mm.

9999696, 9989876, 9990029


133133Fit a new seal to the control housing.

134

T4018982

134Insert the dowels into the gearbox housing.

9996876

135

T4021451

135Ensure that the splitter gear clutch ring is in its rearmostposition, the 2nd/3rd gear clutch ring is in neutral, the1st/reverse clutch ring is in its rear position and therange gear is set to high range (with the range shaft inits forward position and the piston in the range cylinderin its innermost position) and that the shift forks in thecontrol housing are matched to the clutch rings. This isto enable the control housing to be fitted.

136136Carefully lower the control housing so that no gear teethare damaged. It is important for the clutch fork for thesplitter gear to enter the clutch ring correctly. Carefullytap the control housing down at the guide pins.

137137Remove the guide pins.

138138Install the control housing screws and torque tightenthem diagonally.

110 10Nm1159795


139139Connect VCADS, calibrate the gearbox and selectperform test to check that the gearbox is workingproperly.

140140Remove the gearbox from the overhaul stand.

141141Remove the fixture from the gearbox. Install the valveassembly. Clamp the air hose and electrical wiring.

Documents

Gearbox, Disassembly-Inspection-Assembly (Gearbox Removed)