i-shift kaseta wybieraków

Operacja nr

43278-4Data publikacji

Friday, 5 May 2006

Identyfikator

105299097Model

FM

Ścieżka

43/Repair/FM, GSS-AGS, VT2412B/Controlhousing, overhaul. Removed

Identyfikator podwozia

43278-4 Control housing, overhaul

Removed

Note: Since illustrations are used for several different variants, certain details may differ from the variant in question.The essential information in the illustrations is, however, always correct.

IMPACT 3.0 Thursday, 17 June 2010

© Copyright Volvo Parts CorporationInformacje, które zostały tutaj podane są aktualne w czasie pierwszej dystrybucji, jednak mogą ulec zmianie. Należy pamiętać, że kopie drukowane nie są

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A. Position sensor for range cylinderB. Countershaft speed sensorC. Main shaft speed sensorD. Position sensor, 2nd and 3rd cylinderE. Position sensor 1st and reversecylinderF. Position sensor split cylinder

R. Range cylinder2/3. 2/3 cylinder1/R. 1/R cylinderS. Split cylinder

Special tools: 9998588

1

Read off X1 value with the PC-tool or from the label, note X1 value.This is in case the upper cover needs to be replaced. Remove all electrical connections (4) for the



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position sensors.

2

Remove the speed sensors for the main shaft and the countershaft.

3

Remove the screws from the electrical cable attachment plate.

4



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Turn the control housing so that it is standing on the selector forks. Remove the upper cover screws(6 x M8x30).

5

Turn the control housing so that its front edge (split fork side) is against the bench.

6



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Loosen the upper edge of the cover and carefully fold down towards the bench. Remove theelectrical connector carefully to avoid damaging the electrical cabling.

7

Remove the seals for the solenoid valves, the O-ring for the countershaft brake and the covergasket.

8



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Remove the electrical cable screws (hex socket screw). Remove the electrical cable carefully sothat it is not damaged.

9Turn the control housing so that the selector forks are turned upwards.

10

Remove the locking keys for 2nd/3rd cylinder, 1/R cylinder and the split cylinder.

Note: The keys are spring-loaded (all the keys are similar).

11



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Remove all 4 position sensors (all position sensors are similar).

12

Loosen both covers for the split cylinder. Pull out the selector fork with cover and piston. Removethe rear cover.

13



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Remove the piston and sealing ring from the back of the split cylinder.

14

Remove the front cover for the 1/R cylinder, undo the rear cover and pull out the selector fork withcovers and piston.

Note: The 2nd/3rd selector fork shall be in neutral position, so that the inhibitor pin for 1st/R and 2nd/3rd cylinders does.not lock the front cover in place

15



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Remove the piston from the front of the 1st/R cylinder.

16

Loosen both covers for the 2nd/3rd cylinder. Pull out the selector fork with cover and piston.Remove the rear cover.

17



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Remove the piston from the back of the 2nd/3rd cylinder.

18

Remove the cover for the range cylinder. Pull out the piston carefully, so that the piston rod seal isnot damaged.

Note: The bush and seal in the rear end plate of the range cylinder cannot be replaced separately and must thereforebe left in place.

19Clean the housing, check constituent parts. Change any damaged parts.None of the seals or bushes in any of the covers can be replaced separately, therefore the wholecover must be changed.

Note: Blow clean the air passages between the cylinders and solenoid valves thoroughly.When assembling, all piston surfaces, piston sliding surfaces and sealing rings must be greased.



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20

Fit new sealing rings and support strips to the range piston. Grease sliding surfaces and sealingrings.

Note: Lips of the sealing ring.

21Carefully fit the piston into the range cylinder, fit the cover with a new O-ring and torque tighten thebolts.

Specifications:18±1.5 Nm

22



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Press out the spring pin for the 2nd/3rd selector fork. Use a drift and a sleeve as counterhold.Remove the selector fork (carefully tap the spring pin out of the selector fork).

Note: Spring and pin for the position sensor.


23Remove the cover and piston from the piston rod.

24Fit a new piston and a new O-ring into the cover. Fit the cover onto the piston rod.

25



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Fit position sensor pins and springs to the selector fork.

26

Fit the 2nd/3rd selector fork onto the piston rod, press the piston rod to the bottom of the fork andcarefully press in the spring pin using a drift with a sleeve as support.

Note: The opening in the spring pin must be facing the cover and lengthwise in relation to the piston rod.




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27

Fit the 2nd/3rd selector fork with cover and piston into the 2nd/3rd cylinder. Fit the piston and rearcover with a new O-ring. Torque tighten the screws.


28Fit a new O-ring to the rear split cover. Fit the piston into the cylinder with a new piston seal. Fit therear cover and torque tighten the screws.

Note: This must be done now, because it is not possible to torque tighten the screws later.


29



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The 2nd/3rd selector fork is illustrated

Press out the spring pin for the 1st/R selector fork. Use a drift and a sleeve as counterhold.Remove the selector fork (carefully tap the spring pin out of the selector fork).


30Remove the cover and piston from the piston rod.

31Fit a new piston onto the piston rod and a new O-ring onto the cover.

32



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The 2nd/3rd selector fork is illustrated

Fit the 1st/R selector fork onto the piston rod, press in the spring pin carefully using a drift with asleeve as support.



33Fit a new O-ring to the front cover.

34



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Fit a new piston to the front of the cylinder for the 1st/R cylinder.

35

Fit a new O-ring into the front cover of the 1st/R cylinder. Fit the locking pin into the cover.Fit the cover and torque tighten the screws.


36Put the 2nd/3rd selector fork in neutral position and press in the locking pin against the 2nd/3rdselector fork so that it engages in the groove for neutral.

37Fit the selector fork with piston and cover into the 1st/R cylinder. Torque tighten the screws.


38



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Press the spring pin carefully out of the split selector fork. Use a drift and a sleeve as counterhold.Remove the selector fork (carefully tap the spring pin out of the selector fork).


39

Remove the cover and change all the sealing rings on the pistons.

40



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Fit the cover onto the piston rod, fit the selector fork and press in the spring pin carefully using adrift and a sleeve as support.



41Fit the selector fork with piston and cover into the split cylinder.

42Fit the selector fork stop. Torque tighten the screws for the cover and stop.


43



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Fit the locking keys for 2nd/3rd cylinder, 1st/R cylinder and the split cylinder.

44

Fit all position sensors.Torque tighten the screws.


45



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Grease the O-ring on the electric cable.

46

Turn the control housing so that its front edge (split fork side) is on the bench. Fit the electricalcable.

Note: Direction of electric cable.

Part number: 1161053 Locking fluidSpecial tools:

47



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Fit new seals to the solenoid valves, a new O-ring to the countershaft brake and a new gasket tothe cover.

48

Connect the electrical cable for the cover.

Note: Ensure that the electrical cable is not damaged.

The front edge of the control housing must be against the bench. Fit the cover.

49



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Turn the control housing so that it is standing on the selector forks. Fit new screws to the cover (6off M8x30, included in repair kit) and torque tighten.

Specifications:24±4 Nm

50

Turn the control housing so that the upper cover is against the bench.Fit the attachment plate for the electrical cable. Connect the electrical cable to the position sensors.

Note: The electrical cable must lie inside the lug on the range cylinder.

51



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Fit the speed sensors.Torque tighten the screws.


52Perform a functional test .Gear test, removed gearbox, in the PC-tool

Note: Carry out the test with the control housing lying on the upper cover. The control housing must not be touched.during the test, due to the risk for injury

Once the control housing has been fitted to the gearbox, calibration must be performed. If the cover has been changed,the noted value for X1 must be entered into the control unit.



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i-shift kaseta wybieraków

Documents

jednak mog ulec zmianie

naley pamita

position sensors

control housing

electrical cable screws

speed sensors

electrical connections

electrical cabling