FSB 216-001

Field Service Bulletin
Trucks
Volvo Trucks North America
Greensboro, NC USA
Date
This Field Service Bulletin replaces bulletin FSB 216-001
dated 8.2014.
1.2015
Group
No.
Release
216 001 02
Page
1(20)
Twin Mass Flywheel Conversion
Transmission Removed
VN, VT
FSB 216-001, Twin Mass Flywheel Conversion
Transmission Removed
(January 2015)
This document provides the recommended procedure for converting the twin mass flywheel
to a single mass flywheel.
To determine if the flywheel has already been changed from twin mass to single mass, use
premium tech tool (PTT) to access the Sub dataset information under the TEST tab. Open the
1 - Service and Maintenance section and highlight 17034-3 Vehicle Information, Test and
click START. Once the information from the ECU’s has been read, open up MID 130 Gearbox ECU and then open Dataset 2. Sub dataset part numbers 20800153, 20909532,
20923182 or 21901348 indicate the vehicle still has the twin mass flywheel. All other part
numbers means it has been modified to single mass flywheel.
Parts Required
•
Kit, Part Number 22318603
Tools Required
Premium Tech Tool version 2.03.60 or higher
Vocom Diagnostic Connector 88890304
Communication Interface 88890300
Note: Using other interfaces may affect programming speed.
Note: Check Premium Tech Tool version by clicking on Help tab and then click on “About
Tech Tool”.
Note: Information is subject to change without notice.
Illustrations are used for reference only and can differ slightly from the actual vehicle being
serviced. However, key components addressed in this information are represented as
accurately as possible.
Service personnel: Please circulate, read and initial
Service
Manager
Warranty
Administrator
PV729-FSB216-001_V
Workshop
Foreman
Service Technicians
USA67629
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
Procedure
You must read and understand the precautions and guidelines in Service Information,
Function Group 4, “General Safety Practices, Transmission” before performing this
procedure. If you are not properly trained and certified in this procedure, ask your
supervisor for training before you perform it.
DANGER
Do not attempt to repair or service a vehicle without the proper training, tools and service
information. Failure to do so may result in component damage, serious injury or death.
1
CAUTION
To prevent distortion note the sequence of removal of all the fasteners and nuts.
Position the clutch alignment tool (Tool Number 9990024). Remove the fasteners and
nuts.
W4088519
A – Clutch Alignment Tool
Page
2(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
2 Install the pressure plate tools.
W4088520
A – Fixture (Tool Number 9996857)
B – Retainer (Tool Number 9996896)
C – Support (Tool Number 9996996)
3 Remove the pressure plate.
W4088523
Page
3(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
4 Remove the clutch disc.
W4088524
5 Disconnect the engine speed sensor.
W4088525
Page
4(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
6 Remove the engine speed sensor.
W4088527
7 Turn the engine until the small hole in the washer plate is at the 12 o'clock position.
W2088706
Page
5(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
8 Remove four bolts shown in illustration from flywheel.
W2088707
9 Install four special bolts from flywheel lifting kit (tool number J-49004) in flywheel.
W2088707
10 Remove all other bolts from flywheel.
Page
6(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
11 Install lifting plate from flywheel lifting kit on flywheel.
W2088708
12 Install jack adapter from flywheel lifting kit on transmission jack.
W2088709
Page
7(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
13 Position jack adapter on flywheel lifting plate.
W2088710
14 Remove four special bolts from flywheel.
W2088711
Group
No.
Release
216
001
02
Page
8(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
15
WARNING
The flywheel is heavy. Use a transmission jack and the flywheel lifting kit special tools to
lift the flywheel off of the engine to avoid serious personal injury and damage to
components.
Remove flywheel from flywheel housing.
W2088712
16 Remove two outer bolts from top of lifting plate. Position lifting eye from flywheel lifting kit
on lifting plate. Install two outer bolts through lifting eye into flywheel.
Note: Attach the lifting eye with the eye above the center of the flywheel.
W2088713
Page
9(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
17 Position lifting chain and attach hook to lifting eye.
18 Remove the flange.
W2091428
19 Clean the crankshaft flange.
W4088531
20 Check the crankshaft seal for damage, corrosion or excessive wear. Replace if required.
21 Ensure that the flywheel guide pin is correctly inserted in the crankshaft.
Page
10(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
22 To align the flywheel to the crankshaft, lift on the flywheel with the aid of the 2 bolts
(M10x100 mm). Screw in the mounting bolts.
W2091562
23 Use a drift to align the bolt holes. Install all the flywheel fasteners.
Page
11(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
24 To hold the flywheel in position, install the rotation tool (Tool Number 88800014 or
88840317).
W4088532
A – Rotation Tool
25 Torque the flywheel fasteners in sequence. Torque fasteners to 60 ± 5 Nm (44 ± 4 ft-lb).
Torque each fastener in sequence an additional 120 ± 10 degrees.
W4088533
Page
12(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
26 Remove the rotation tool. Install the plug.
W4088534
27 Install the engine speed sensor. Torque fastener to 8 ± 2 Nm (6 ± 1.5 ft-lb).
Note: Install a new O-ring when reinstalling the engine speed sensor
W4088527
Page
13(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
28 Reconnect the engine speed sensor.
W4088525
29 Install special tools (Tool Numbers 9991801 [B] and 9992564 [A]). Install the pilot bearing
into the flywheel.
W4088535
A – Mandrel
B – Handle
Page
14(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
30 Install the new clutch disc.
W4088524
31 Install new pressure plate.
Note: Install the clutch disc and pressure plate together.
W4088520
A – Fixture (Tool Number 9996857)
B – Retainer (Tool Number 9996896)
C – Support (Tool Number 9996996)
Page
15(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
32
CAUTION
If the pressure plate fasteners are torqued out of sequence distortion damage can occur.
Torque pressure plate fasteners in sequence to 53 ± 5 Nm (39 ± 4 ft-lb).
W4088519
A – Clutch Alignment Tool
33 Remove the clutch release bearing hose zip ties.
W4088540
Page
16(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
34 Remove the clutch release bearing hose.
W4088541
35 Remove the clutch cylinder.
W4088542
Page
17(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
36 Install the spacer disc.
W4088543
37 Install the new clutch cylinder with the longer mounting fasteners included in the kit.
Torque fasteners to 45 ± 5 Nm (33 ± 4 ft-lb).
38 Check the clutch release bearing hose O-rings for damage. Replace the O-rings (part
number 22485772), if necessary.
W4088544
Page
18(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
39 Install the clutch release bearing hose. Install cable ties to secure the hose into position.
W4088541
40 Install the transmission. Refer to Function Group 43.
41 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
fasteners to 20 ± 2 Nm (15 ± 1.5 ft-lb).
42 Using Premium Tech Tool run conversion kit(s) as listed below::
Note: Once the hardware conversion has been completed, run Conversion Kit 85142350
only for US07 and EM-USA10 vehicles. For EOBD-2013 and EM-USA14 vehicles, run
Conversion Kit 1 and Conversion Kit 2 in order.
Vehicle
Conversion Kit 1
Conversion Kit 2
VN, VT, US07, ATO3112C,
ATO3112D
Not Applicable
85142350
VN, EM-USA10
Not Applicable
85142350
VN, EOBD-2013
85142351
85142352
VN, EM-USA14
85142351
85142352
43 Use PTT to program the transmission electronic control unit (TECU). From the Main Menu
select Program and then Program Electronic Control Unit 1700-08-03-39. Then click Start.
Select Transmission ECU (TECU). Select Program to update the TECU with the latest
software.
44 When programing is complete, select Calibrate from the Main Menu. Select 4320-07-0301 Gearbox, clutch, engagement point.
45 When Calibration is complete, clear any diagnostic trouble codes (DTC) and Finish Work.
Page
19(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
Page
20(20)
Reimbursement
This repair may be eligible for reimbursement if a product failure was
experienced within time and mileage limits of the applicable Warranty
coverage. Reimbursement is obtained via the normal claim handling
process.
Reimbursement
UCHP
Reimbursement
eWarranty
Claim Type (used only when uploading from the Dealer Bus. Sys.)
W
W
Primary Labor Code
2160-03-09-01 —
1.7 hrs.
21618–2–00 — 1.7
hrs.
Causal Part
21905650
21905650
Labor Code
Volvo Trucks North America reserves the right to make any changes in design or to make
additions to or upon its products without incurring any obligations to install the same on
vehicles previously built.