43110-2 Bearing, output shaft, replaceAs the same illustrations are reused for different variants, some details may differ for the variant you are working on.The essential information in the illustrations is, however, always correct.ContentsDisassembling the gearboxDisassembling the range gearAssembling the range gearAssembling the gearboxPart number: 3092340Special tools: 9986485, 9989876, 9990027, 9990029, 9990031, 9990084, 9992241, 9992337, 9992619, 9992671,9994078, 9996081, 9996156, 9996222, 9996315, 9996479, 9996483, 9996788, 9996901, 9996905, 9996917,9996925, 9998051, 9998185, 9998542, 9998570 , 9998597, 9999696, 9999737, 88800015, 88800174Other special equipment: 1159794, 1159795, 1159796Disassembling the gearbox1Remove the gearbox, see. 43170-1 Gearbox, remove2Clean the outside of the gearbox.Note: Plug nipples and protect valves during high pressure washing.3 Chassis ID Path4/Repair/B12R, AT2412C/Bearing, output shaft, replaceModel IdentityB12R 128555499Publishing Date Operation No.Tuesday, 9 February 2010 43110-21 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Fit the intermediate flange on to the fixture plate. With the aid of the arms, fit the fixture plate to the gearbox. Securethe gearbox into the unit stand.Special tools:,,,9986485 9990031 9996905 99997374If the gearbox retarder continue with step . has no 652 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Alternative 13 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Alternative 2WarningHot oil can cause burns. Use protective gloves.Put an suitable vessel under the retarder's drain plug. Remove the two drain plugs (C) for retarder oil on the heatexchanger. Also loosen the filler plug (A) and the vent plug (B) for faster draining.64 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Drain the gearbox oil off.7Remove the oil filter drain plug. Refit the drain plug after the oil has finished draining.85 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Connect the PC tool and carry out VCADS Pro Operation, Gearbox activation, control housing removal and 40091-3installationTo remove the control housing, the splitter gear must be in its rear position, 2nd and 3rd in neutral, and 1st/reverse inits rear position and the range gear set to high range (the forward position).9Remove the electrical connector for the clutch valve assembly in the control housing.106 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the screws and control housing. If necessary, carefully use a crowbar to loosen the control housing from itsguide pins.Special tools: 999233711If the gearbox retarder continue with step . has no 14127 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the retarder temperature sensor from the heat exchanger, or alternatively remove the connector from theplate.13Alternative 18 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Alternative 2Remove the three screws securing the heat exchanger and retarder cooler.14Turn the gearbox so that the output shaft flange faces upwards.159 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the companion flange nut and O-ring.Special tools: 99985701610 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Pull off the companion flange.Special tools:,,,,,9990084 9992619 9992671 9996156 9996222 999859717If the gearbox retarder continue with step . has no 201811 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the four nuts securing the retarder to the range housing (A, B, C and D in the illustration).19Carefully lift the retarder away from the gearbox.20Fit the adapter and lifting eye into the output shaft.Special tools:,9996479 99969252112 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the plug, spring and blocking body for the range function. If necessary use a magnet to pull out the blockingbody.22Remove the range housing securing screws.Note: If the gearbox has a retarder, do not forget to remove the bolts in the retarder mounting.2313 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Press the basic housing and range housing apart. Use a press tool.Special tools: 999805124Lift 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.25Remove the oil distributor pipe. Use a socket.Special tools: 999002726Remove the circlip securing the high range synchronizer.14 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 201227Remove both halves of the washer.28Fit both the puller halves on to the high range synchronizer hub.Special tools: 8880001529Fit 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.Special tools:,,,,88800015 9992619 9992671 9996889 999854215 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 201230Fit the other half of the puller 9998542. Fit the hydraulic pump. Press off the high range synchronizer.Special tools: 999622231Lock the gears with the holder for the clutch sleeves.Special tools: 999002932When measuring the mainshaft and countershaft, gear 2 LS shall be engaged. The splitter gear clutch ring in its position. Without overdrive: frontmost The splitter gear clutch ring in itsposition. With overdrive: rearmost33Turn the gearbox 1/2 turn.Remove the countershaft brake, see 43132-5 Brake, intermediate shaft, overhaul3416 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Turn the gearbox back 1/2 turn.Fit screw 9996917 on the main shaft and screw 9996483 on the countershaft.Special tools:,9996917 999648335Rotate the shaft 20 turns.3617 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Attach the dial gauge to the magnetic stand. The tip of the dial gauge should touch the sun wheel. Zero the dial gaugeand mark up the measurement point.Special tools:,9989876 999969637Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off any play at the markedposition.38Turn the gearbox back 1/2 turnRemove the dial indicator and rotate the shaft 20 turns.39Fit the dial indicator to the magnetic stand. The tip of the dial indicator is to be in contact with special tool 9996483.Zero the dial indicator and mark up the measuring point.Special tools:,,9989876 9999696 999648340Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off any play at the markedposition.18 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 201241Note: If axial play has been measured, adjust the main shaft and countershaft, to achieve the correctpreloading.If there is axial play adjust the main shaft and countershaft, see. 43185-5 Main shaft and countershaft, adjustIf no axial play is measured, it is assumed that the shafts are correctly preloaded.42Remove the dial indicator.43Fit the countershaft brake, see. 43132-5 Brake, intermediate shaft, overhaulSpecifications:45 5 NmDisassembling the range gear44Remove the lifting eye and adapter.Special tools:,9996479 99969254519 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the seal ring from the housing.Special tools: 99940784620 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the toothed wheel for the speedometer. Remove the vehicle speed sensor.47Remove the lock ring retaining the output shaft bearing in the range housing.21 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Special tools: 998818548Remove the bolts retaining the range gear in the housing.49Remove the range gear.5022 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Press the planetary gear out of the housing.Note: Ensure that the planetary gear runs freely and that it is not dropped and damaged.51Remove the planetary gear and range housing from the press.52Press out the output shaft bearing.Special tools: 999224123 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Assembling the range gear53Clean the range housing.54Press a new bearing home into the range housing.Special tools: 99967885524 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Fit the thickest possible lock ring for the bearing. The maximum permitted clearance (A) is 0.1 mm.Use a feeler gauge to measure the clearance.Special tools: 9988185Specifications:Max. 0.1 mm5625 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Press the range housing onto the planetary gear and output shaft.Special tools:,9996759 999692457Install the toothed wheel for the speedometer sensor. Install the vehicle speed sensor with an undamaged gasket.26 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Torque tighten the vehicle speed sensor.Other special equipment: 1159794Specifications:25 5 Nm58Half fill the space between the seal lips with grease.Note: Do not grease the axial surface of the sealing ring.59Shaft 70 mm diameterPut the seal onto the mandrel and drive it into the range housing. For a 70mm shaft, use 9998575.Special tools: 9998575Specifications:70 mm6027 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Shaft 80 mm diameterFor a 80mm shaft, use 88800174. The ring that is part of tool 88800174, shall only be used on VT boxes.Special tools: 88800174Specifications:80 mm6128 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Fit the range unit in the range housing and torque tighten the bolts.Note: Tighten the bolts diagonally.Other special equipment: 1159795Specifications:110 10 NmAssembling the gearbox6229 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Press in the synchronizer for high range.Special tools:,,,,88800015 9992671 9996222 9996315 999854263Fit both the washer halves.64Fit the high range circlip.30 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 201265Remove the forks (9990029) holding the clutch sleeves in place. Remove the screws (9996917 and 9996483) from theshafts.Special tools:,,9990029 9996483 999691766Oil and fit new O-rings. Install the oil distribution piping. Torque tighten the oil distribution piping. Use a socket.Special tools: 9990027Other special equipment: 1159795Specifications:250 35 Nm6731 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Apply a string of sealant, part number 3092340 to the basic housing face, as illustrated.Part number: 309234068Fit and onto the range unit output shaft. Position the range housing over the gearbox housing. 9996479 9996925Lower and line up the piston rod and planet wheel. Torque tighten the range housing bolts.Special tools:,9996479 9996925Other special equipment: 1159795Specifications:110 10 Nm32 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 201269Turn the gearbox 1/4 turn, so that the control housing can be fitted from above.70Position a new control housing gasket.71Insert the dowels into the gearbox housing.72Ensure that the splitter gear clutch ring is in its rearmost position, the 2nd/3rd gear clutch ring is in neutral, the1st/reverse clutch ring is in its rearmost position and the range gear is set to high range (with the range shaft in its frontmost position and the piston in the range cylinder in its innermost position) and that the selector forks in the control33 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012housing are matched to the clutch rings.This is to enable the control housing to be fitted.73Carefully lower the control housing so that no gear teeth are damaged. It is important for the clutch fork for the splittergear to enter the clutch ring correctly.Carefully tap the control housing down at the guide pins.74Remove the guide pins.75Install the control housing screws. Torque tighten the bolts diagonally.Other special equipment: 1159795Specifications:110 10 Nm76Fit the key, spring and plug for the range.77Carry out the following VCADS Pro operations using the PC tool.40105-4 Gearbox, calibration (gearbox removed)43116-4 Gears, test (gearbox removed)78If the gearbox retarder continue with step . has no 817934 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Turn the gearbox 1/4 turn, so that the retarder can be fitted from above.80Fit the retarder with a new O-ring, grease it with silicon grease. Guide the screws into their holes, and push in theretarder until it bottoms into position. Fit the nuts and tighten them by hand as illustrated, in the order A, B, C and D.Note: After the retarder has been tightened, there should be a gap between the retarder and the range housing. Torquetighten the nuts in order A,B,C, and D and then 1st and 2nd angle tightening.Other special equipment: 1159795Specifications:30 Nm45545581Replace the V-ring on the companion flange; the V-ring shall lie against the stop on the companion flange.Note: Check the flange's mating surfaces to ensure that there is no visible damage.8235 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Press the companion flange onto the shaft.Note: The companion flange must not, under any circumstances, be heated up or hit with a hammer. The companionflange shall be fitted and pressed home on the output shaft using the special tool provided. It is very important that theflange is pressed completely home before the nut is tightened. If the flange is not pressed completely home, damagecan be caused to the output shaft bearing or the range oil pipe.Special tools:,,,,9992671 9996222 9996315 9996901 999692583Fit the counterhold on the companion flange. Fit a new O-ring and nut, and torque tighten.36 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Special tools: 9998570Other special equipment: 1159796Specifications:400 Nm+15050 /84Lock the flange nut in both recesses on the flange using a mandrel.Note: The punch must have a rounded tip and the tabs should be driven in until they bottom. Check that no crackshave occurred.85Turn the gearbox back 1/4 turn.86If the gearbox retarder continue with step . has no 908737 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Fit new O-rings on the heat exchanger and range housing, grease them with silicon grease.Lift the heat exchanger so that the narrow sleeves go into their holes.8838 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 201239 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Fit the securing bolts. Pull the heat exchanger into place using the upper rear bolts, and tighten them to the specifiedtorque.Other special equipment: 1159794Specifications:85 Nm89Fit the temperature sensor for the retarder.9040 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Remove the oil filter cover and guide sleeve.Note: There will be a little oil left in the cover.91Fit a new gearbox filter.Specifications:505 Nm92Fit the gearbox, see 43172-1 Gearbox, install93If the gearbox retarder continue with step . has no 969441 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Alternative 142 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012Alternative 2Tighten the two oil drain plugs (C) to for alternative 1 and for alternative 2. 16 Nm 13 NmFill the retarder with oil. Oil volume, litreRetarder ProductionfillingServicefillingHeat exchangercompletelydrained fromoilRET-TH 6,1 5,4 6,1For oil grade, see. Preventive maintenance intervalsOther special equipment: 1159794Specifications:16 Nm13 Nm95Fit the ventilation plug (B) and tighten it to. 13 NmOther special equipment: 1159794Specifications:13 Nm96Fill the coolant system, see. function group 26.43 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 201297Fill the gearbox with oil.44 / 44 Copyright Volvo Group North AmericaThe information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.IMPACT 3.0 Thursday, 20 September 2012