gearbox, disassembly-inspection-assembly (gearbox removed)

Service BulletinVolvo Truck CorporationGteborg, Sweden Trucks

Date Group No. Release Page

10.2010 431 256 18 1(49)

Gearbox, Disassembly-Inspection-Assembly

(Gearbox removed)

FH/FM

AT2412C, AT(O)2512C, AT2812C,ATO3112C

Gearbox, Disassembly-Inspection-Assembly

T4021207

89002260ENG46029 English

Volvo Truck Corporation Date Group No. Release PageService Bulletin 10.2010 431 256 18 2(49)

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.

Note: For replacement of GCU (Gear Control unit) or TECU, read first Function Group4319, Information type Diagnostics MID 130 PID 160 Parametersetting.

WARNING

Always wear safety glasses when using compressedair in the gearbox.

General information about axial play

For clutch housing with part number 20483498 at AT2412C and ATO2512C

T4059270

Replace with new part. See step 23.

Note: To check the part number remove GCU.

Clutch housing with other part numbers

If the criteria 1 and 2 are fulfilled, glue theouter race of the input and counter shaftbearings into position. Use VOLVO gluewith part number 8701374. See step 92and 93.

1 Pretension the main and coutershaft.

2 Check axial play on the main andcounter shaft. It should be maximum0.25 mm. See step 53.

3 Check radial play on the inputand counter shaft. The outerraces should not be loose and/ornot be possible to rotate in roomtemperature. See step 78.

If the criteria 1 or 2 is not fulfilled, replacethe clutch housing.

Basic housing

If the feeler gauge can be inserted replacethe basic housing

Check the gap between the basichousing and bearing outer race on themain and counter shaft. Use feelergauge with thickness 0.05 mm andmaximum width 10 mm. See step 64.

If the feeler gauge can not be inserted usethe O-ring kit. See step 111 and 121.


Special tools: 9986485, 9989876, 9990027,9990028, 9990029, 9990031, 9990120, ,9992000, 9992215, 9992337, 9992613,9992619 , 9992671, 9996041, 9996042,9996081, 9996176, 9996222, 9996239,9996315, 9996479, 9996483, 9996876,9996889, 9996905, 9996910, 9996917,9996925, 9998051, 9998401, 9998542,9999696, 9999737, 88800211, 88800006,88800015, 88800033, 88800034,88800035, 9992003

Other special equipment 88890148,88890149

ContentsDisassembly, page 4 .

Inspection, page 31.

Assembly, page 31.


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

23

T4059270

23Check the part number on the clutch housing. Partnumber 20483498 on AT2412C and ATO2512C shallbe replaced with a new.

2424If the gearbox is equipped with a retarder, perform step25 27. Otherwise go to step 28.

25

T4020965

25Remove the retarders temperature sensor from theheat exchanger or alternatively, remove the connectorfrom the plate.


26

T4020966

26Remove the retarder wiring cable ties.

27

T4020967

27Remove the three screws securing the heat exchangerand retarder cooler.

2828Turn the gearbox so that the output shaft flange facesupwards.

29

T4021488

29Fit counterhold 9998570.Remove the companion flange nut and O-ring.

9998570


30

T4022460

30Remove the companion flange.

9990084, 9992619, 9992671, 9996156, 9996222,9998597

31

C4052785

31Remove the plug, spring and blocking body for therange function. If necessary use a magnet to pull outthe blocking body.

3232If the gearbox is equipped with a retarder, perform step33 34. Otherwise go to step 35.


33

T5012262

33Remove the four nuts securing the retarder to the rangehousing (A, B, C and D in the illustration).

3434Carefully lift the retarder away from the gearbox.

35

T4023008

35Remove the range housing securing screws.

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

36

T4023007

36Fit the adapter and lifting eye into the output shaft.

9996479, 9996925


37

T4023009

37Split the main housing and range housing. Use presstool.

9998051

3838Lift the range housing away carefully.

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

39

T4021428

39Remove the oil distributor pipe. Use a socket.

9990027

40

T4021426

40Remove the circlip securing the high rangesynchronizer.


41

T4021427

41Remove both halves of the washer.

42

T4021425

42Fit both the puller halves on to the high rangesynchronizer hub.

88800015

43

T4021429

43Fit 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


44

T4021430

44Fit the other half of the puller 9998542. Fit the hydraulicpump. Press off the high range synchronizer.

9996222

45

T4023474

45Check the part no. of the spacer sleeve and check TPI431-033 in parts information.If necessary, replace the spacer sleeve according tosteps 46 Remove the old spacer sleeve., page 19 48 Fit the new spacer sleeve.

9996222, 9992671, 88800246, 9996315, 9996917, page 20Otherwise go to step 49 Fit screw 9996917 on to the main shaft and screw9996483 on the counter shaft.

9996917, 9996483, page 20

46

T4023475

46Remove the old spacer sleeve.


47

T4023476

47Transfer the piston rings to the new spacer sleeve.

48

T4023477

48Fit the new spacer sleeve.

9996222, 9992671, 88800246, 9996315, 9996917

49

T4021483

49Fit screw 9996917 on to the main shaft and screw9996483 on the counter shaft.

9996917, 9996483


50

T4021484

50Rotate the shafts 20 turns.

51

T4021485

51Attach the dial gauge to the magnetic stand. The tip ofthe dial gauge should touch the sun wheel.Zero the dial gauge and mark up the measurementpoint.

9989876, 9999696

5252Turn the gearbox 1/2 turn. Lift the measuring probeand turn the shaft 20 turns, read off the backlash at themarked position and note it.

5353Check axial play on the main shaft and counter shaft.Maximum axial play is 0.25 mm.If the axial play is more than maximum, replace theclutch housing with a new.

5454Turn the gearbox 1/2 turn.

55

T4021483

55Remove

Dial indicator 9989876 Magnetic stand 9999696 Bolt 9996917 Bolt 9996483

9989876, 9999696, 9996917, 9996483


56

T4021431

56Remove the reversing shaft centre screw.

57

T4059192

57Remove the rear cover, adjustment shim and anypossible O-ring for the counter shaft.

58

T4021432

58Fit the puller and spindle to the reversing shaft.

9996315, 9996917


59

T4021433

59Fit the hollow drift, hydraulic cylinder and hydraulicpump to the spindle.

9990120, 9992671, 9996222

6060Press out the reversing shaft.

61

T4020987

61Remove the oil pump with the reverse gear pinion.

62

T4059189

62Remove the rear cover and any possible O-ring for themain shaft and where applicable the oil pipe for theoverdrive gear.

Note: Tow alternatives, A and B


63

T4021435

63Remove the adjustment shim for the main shaft.

64

T4059304

64Use feeler gauge with thickness 0.05 mm and maximumwidth 10 mm to check the gaps.If the feeler gauge can be inserted, replace the basichousing.

6565Turn the gearbox so that the input shaft (the shaft withdiscs) faces upwards.

66

T4020990

66Remove 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.


67

T4020991

67Remove the air hose for the clutch cylinder and the airpipe for the counter shaft brake.

68

T4020992

68Remove the counter shaft brake.


69

T4020993

69Remove the piston A and spring B for the counter shaftbrake.

7070Remove the clutch housing.

71

T4019239

71Remove the air pipe nipple for the counter shaft brakepipe.


72

T4019240

72Remove the sleeve from the intermediate shaft.

7373Remove the magnet located between the clutchhousing and the lower part of the base housing. Cleanthe magnet.

74

T4021049

74Prepare 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

75

T4021768

75Make 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.


76

T4021767

76Carefully lift out the shaft assembly and place it in thewooden fixture.

7777Remove the lifting tool from the shaft assembly.

78

T4060707

78Check radial play on the counter shaft and the inputshaft. If the outer races are loose and/or possible torotate in room temperature, replace the clutch housing.


79

T4021545

79Pull the counter shaft 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

80

T4021544

80Pull the input shaft outer race out of the clutchhousing. Use a puller, yoke, cylinder, pump and spindle.


88800033, 88800034, 9992671, 9996041, 9996222


81

C4060678

81Drive the outer race of the counter shaft rear bearingout of the gearbox housing. Use a drift and handle.


A= 9992000B= 9996081

9992000, 9996081

82

T4019212

82Drive the outer race of the main shaft rear bearingout of the gearbox housing. Use a drift and handle.


9992613, 9996176

83

T4021270

83Remove the oil screen and the overflow valve.


Inspection84

84Clean 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 package.

8585Lubricate all parts with gearbox oil before installation.

Assembly86

T4021804

86Drive 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 counter shaft.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.

87

T4021270

87Turn the gearbox over 1/2 turn. Fit the oil screen andoverflow valve. Torque tighten the valve.

45 5 Nm88890148


88

T4021049

88Assemble 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

8989Carefully lift the shaft assembly into the gearboxhousing.

9090Remove the fixture and the three lifting arms from theshafts.

91

T4019239

91Install the nipple for the air pipe for the counter shaftbrake.


92

T4021542

92Use VOLVO glue with part number 8701374 to fix thecounter shaft outer race into position.When changing the counter shaft outer race in theclutch housing, press it in so that it bottoms in theclutch housing.

9992003, 9996041, 9996042, 9992671, 9996222

93

T4021543

93Use VOLVO glue with part number 8701374 to fix theinput shaft outer race into position.When changing the input shaft outer race in theclutch housing, press it in so that it bottoms in theclutch housing.

9992671, 9996041, 9996042, 9996081, 9996222,9998401

94

T4019215

94Apply VOLVO approved high-temperature liquidgasket to the main housings mating surfaces to theclutch housing according to the illustration. Fit themagnet.


9595Put the clutch housing on the base housing. Make surethat the guide dowels enter their holes in the clutchhousing.

9696Install the clutch housing screws and torque tightenthem alternately.

110 10 Nm88890149

97

T4021445

97Remove the seal for the input shaft. Use a lever.

Note: Replace the seal if necessary.

9992337

98

T4059186

98Press in the seal with a drift, (A) 88800211.

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.

88800211



100

T4021435

100Install a shim with thickness approximately 0.9 mm.

101

T4059189

101Install the rear cover.Torque tighten diagonally.

Note: Two alternatives, A and B

405 Nm

102

T4059190

102Install a shim with thickness approximately 0.9 mm.


103

T4059192

103Install the counter shaft cover.Fit the screws and torque tighten them diagonally.

405 Nm

104

T4019217

104Lock the gears with the holder for the clutch sleeves.

Note: When measuring the main and counter shaft,gear 2 LS shall be engaged.Without overdrive: The splitter gear clutch ring in itsfrontmost position.With overdrive: The splitter gear clutch ring in itsrearmost position.The counter shaft brake must not be engaged.

9990029

105

T4021483

105Fit screw 9996917 on the main shaft and screw9996483 on the counter shaft.

9996917, 9996483

106

T4021484



107

T4021485

107Attach 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

108108Turn the gearbox 1/2 turn. Lift the measuring probeand turn the shaft 20 turns, read off the backlash at themarked position and note it.

109

T4059189

109Turn the gearbox 1/2 turn.Remove the main shaft cover.


110

T4021435

110

Install a shim that is between 0.1 and 0.2 mm thickerthan the measured play together with the existing shim.This gives a preload of between 0.1 and 0.2 mm.


111

T4059188

Alternative 1

T4059187

Alternative 2

111Install O-ring.

Note: Two alternatives, 1 and 2

112

T4059189

112Install the main shaft cover.Torque tighten the screws diagonally.


405 Nm


113

T4021484


114

T4021486

114Turn the dial gauge to the counter shaft. The tip of thedial gauge should touch the counter shaft. Zero the dialgauge and mark up the measurement point.

115115Turn the gearbox over 1/2 turn.

116116Lift the tip of the dial gauge and rotate the countershaft at least 20 turns. Read off the clearance from themarked measurement point and note the value.

117117Turn the gearbox over 1/2 turn.

118

T4021483

118Remove

Dial indicator 9989876 Magnetic stand 9999696 Bolt 9996917 Bolt 9996483

9989876, 9999696, 9996917, 9996483


119

T4059192

119Remove the counter shaft cover.

120

T4059190

120Install a shim that is between 0.1 and 0.2 mm thickerthan the measured play together with the existing shim.This gives a preload of between 0.1 and 0.2 mm.

121

T4059191

121Install O-ring.

122

T4059192

122Remove the counter shaft cover.


123

T4021482

123Fit a new gasket on the oil pump.

124

T4020987

124Install 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 Nm88890148

125

T4059192

125Install the counter shaft coverr.

Note: Torque tighten the screws diagonally.

405 Nm88890148

126126Where applicable fit the overdrive oil pipe.


127

T4022457

127Press in the synchronizer for high range.

88800015, 9992671, 9996081, 9996222, 9996315,9998542

128

T4021427

128Fit both the washer halves.

129

T4021426

129Fit the high range circlip.

130

T4019217

130Remove the forks 9990029 holding the clutch sleevesin place.

9990029


131

T4021428

131Oil and fit new O-rings. Install the oil distribution piping.Torque tighten the oil distribution piping. Use a socket.

9990027250 35 Nm88890149

132

T4023186

132Apply VOLVO approved high-temperature liquidgasket.

133

T4023007

133Fit 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 10Nm88890149

134134If the gearbox is equipped with a retarder, performsteps 135 140. Otherwise go to step 141.


135

T5012262

135

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 Nm4588890148


137137Install new O-rings on the heat exchanger and therange housing. Apply silicon grease to the O-rings.

138

T4020967

138Lift 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 Nm88890149

139

T4020965

139Fit the temperature sensor for the retarder.


140

T4020966

140Clamp the retarder wiring.

141

C4052785

141Install the blocking body, spring and plug for the rangefunction.

142

T4020964

142Install the oil filter housing with a new seal and a newoil filter. Where applicable, fit the oil cooler. Torquetighten the bolts.

20 3 Nm88890148



144

T4019225

144Fit a new gasket between the brake and the clutchhousing.

145

T4019226

145Add the discs alternately. Begin and end with a steeldisc (two friction discs and three steel discs).

146

T4019286

146Fit the sleeve with a new O-ring, spring and piston.


147

T4020992

147Fit the cylinder over the disc assembly and torquetighten the screws.

45 5 Nm88890148

148148Clean the nipple threads. Fit the brake pipe. Screwthe nuts fully on by hand. Then tighten with a socketspanner a further 3/4 turn.

149149Fit the clutch cylinder and air hose. Secure the hosewith a clip. Torque tighten the bolts.

45 5 Nm88890148


151

T4019229

151Fit 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


152152Fit a new seal to the control housing.

153

T4018982

153Insert the dowels into the gearbox housing.

9996876

154

T4021451

154Ensure 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.

155155Carefully 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.

156156Remove the guide pins.

157157Install the control housing screws and torque tightenthem diagonally.

110 10Nm88890149


158158Connect VCADS, calibrate the gearbox and selectperform test to check that the gearbox is workingproperly.

159159Remove the gearbox from the overhaul stand.

160160Remove the fixture from the gearbox. Install the valveassembly. Clamp the air hose and electrical wiring.

gearbox, disassembly-inspection-assembly (gearbox removed)

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