FSB 432-013

Field Service Bulletin
Trucks
Volvo Trucks North America
Greensboro, NC USA
Date
This bulletin replaces bulletin “FSB 432-013, AMT High Range
Cone Replacement” released 04.2014.
5.2014
Group
No.
Release
432 013 02
Page
1(32)
AMT High Range Cone
Replacement
VN, VHD, VAH, VT
FSB 432-013, AMT High Range Cone Replacement
(May 2014)
This document provides the recommended procedure for replacing the high range section of
the Automated Manual Transmission (AMT) including the high range cone.
Required Parts:
•
1 – Part Number 85013966, I-Shift Range Synchronizer Service Kit
Service personnel: Please circulate, read and initial
Service
Manager
Warranty
Administrator
PV729-FSB432-013
Workshop
Foreman
Service Technicians
USA64911
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
Procedure
You must read and understand the precautions and guidelines in Service Information,
group 40, "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 this vehicle without having sufficient training, the correct
service literature and the proper tools. Failure to follow this could make the vehicle unsafe
and lead to serious personal injury or death.
DANGER
Before beginning any work on any part of the air system, be certain that the air pressure
has been released. Failure to do so may cause a component to violently separate, which
can result in serious personal injury.
Note: Special tools: 85108826, 9996876
1 Using Premium Tech Tool, perform the “Gear Activation, Control Housing (for Removal/
Installation)”. Follow the instructions as outlined within Premium Tech Tool.
Note: If Tech Tool is unable to activate the necessary gears for control housing removal,
follow the manual activation steps outlined in this procedure after transmission removal.
2 Secure the vehicle for service by parking it on a flat level surface, applying the parking
brake, chocking the rear wheel, and placing the transmission in neutral.
3 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
4 Drain the air system.
5 Raise the vehicle and support with jack stands.
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2(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
6 Disconnect the transmission oil cooler hoses from the filter housing. Use tool 85108826.
W4002890
7 Remove the drive shaft.
Note: Remove the universal joint caps and the bolts holding the intermediate bearing to
the support bracket (if equipped).
Note: Mark the position of the bolts on the bracket so that the intermediate bearing is
installed in exactly the same position as before. Position the shaft aside.
T4018155
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3(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
8 Disconnect the air supply hose at the rear of the transmission.
W4002940
9 Remove the tie straps securing the wiring harness to the transmission.
10 Disconnect the electrical harness at the control housing, speed sensor, and the two
chassis connectors.
Note: Position the harness out of the way.
W4002941
11 Remove the cab engine cover.
12 Remove the transmission-to-engine mounting bolts along the bottom and sides of the
clutch housing.
Note: Do not remove the top four transmission-to-engine mounting bolts at this time.
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4(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
13 Position the transmission jack and secure the transmission to the jack
14 Remove the top four transmission-to-engine mounting bolts.
15 Carefully pull the transmission back until the input shaft clears the pressure plate. Lower
the transmission and pull it out from under the vehicle.
Note: While lowering the transmission, periodically check around it to assure nothing is
caught or hung up on it such as wiring or air hoses.
16 Disconnect the clutch valve wiring connector at the control housing.
W4002881
17 Disconnect the clutch control valve air supply tube at the upper control housing fitting.
W4002947
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
18 Remove the control housing mounting bolts.
W4002951
19 Remove the six TECU mounting bolts.
Note: It is only necessary to perform this step if; replacing the control housing without a
new TECU or, if manually performing the “Gear Activation, Control Housing (for Removal/
Installation)”. If Premium Tech Tool activated the necessary gears, proceed to step 23.
W4002952
Page
6(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
20 Manually perform the “Gear Activation, Control Housing (for Removal/Replacement)” as
outlined in the next three steps.
Note: The next three steps are performed only if Tech Tool could not activate the
necessary gears for control housing removal.
21
CAUTION
Electrical components, including the wiring harness inside the transmission control
housing, are delicate. Handle with extreme care. Failure to do so may result in damage
to components.
Gently lift the top edge of the upper cover and angle it down carefully against the clutch
housing. Carefully disconnect the electrical connection and remove the top cover.
Note: Do not apply tension or weight to the wiring harness or connector.
W4002953
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
22 Using compressed air, apply air pressure to the appropriate bore holes to place the
transmission gears in the proper position for control housing removal.
Note: It is necessary to rotate the input shaft while engaging the splitter section to mesh
the gears.
Note: It is necessary to rotate the output shaft while engaging the range section to mesh
the gears.
Note: It is necessary to rotate the output or input shaft while engaging reverse to mesh the
gears.
Note: For over drive transmissions, the transmission must be positioned as follows:
* Low Split
* High Range
* 2nd/3rd — Neutral Position
* 1st/Reverse — Reverse Position
W4002895
Over Drive Transmission
1 – High Range
2 – 3rd Gear
3 – Low Range
4 – 2nd Gear
5 – 1st Gear
6 – High Split
7 – Reverse Gear
8 – Low Split
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
Note: For direct drive transmissions, the transmission must be positioned as
follows:
* High Split
* High Range
* 2nd/3rd — Neutral Position
* 1st/Reverse — Reverse Position
W4002895
Direct Drive Transmission
1 – High Range
2 – 3rd Gear
3 – Low Range
4 – 2nd Gear
5 – 1st Gear
6 – Low Split
7 – Reverse Gear
8 – High Split
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9(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
Note: If 2nd or 3rd gear is engaged, it will be necessary to position that gear set to neutral
before attempting to engage reverse.
Note: To engage neutral for the 2nd/3rd gear set, it will be necessary to gently apply air to
the bore holes. If too much air is applied, it will engage one of the two gears. To aid
positioning, do not rotate the shaft when attempting to position this gear set.
T4021451
Page
10(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
23
CAUTION
Gentle consistent pressure should be used to lift the control housing from the
transmission. Applying excessive force is not necessary or needed, and may result in
damage to components.
CAUTION
Always install the alignment pins before removing the control housing to prevent
damage to the transmission main shaft speed tone ring and the shift control.
Note: Use tool 9996876.
Install the alignment pins through the control housing into the transmission. Using a pry
bar, gently separate the control housing from the locating pins on the transmission, then
remove the control housing.
Note: If the control housing does not separate from the transmission while applying gentle
pressure upward, it may be necessary to refer back to Step 23 or Step 24 before
attempting control housing removal again.
Note: Exercise care during removal to keep from damaging the tooth wheel in the
transmission.
W4002955
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11(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
24
WARNING
Hot oil can cause burns. Use protective gloves.
Remove the transmission oil drain plug and drain the transmission oil into a suitable
container. Install the transmission oil drain plug and tighten to specification, refer to
Function Group 431, Transmission, Mechanical.
T4022639
25 Remove the oil filter oil drain plug and drain the transmission oil into a suitable container.
Install the oil filter drain plug and tighten to specification, refer to Function Group 431,
Transmission, Mechanical.
W4002889
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12(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
26 Turn the transmission so that the output shaft flange faces upwards.
27 Remove the plug, spring, and blocking body for the range function.
Note: If necessary, use a magnet to pull out the blocking body.
C4052785
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
28 Split the main housing and range housing using the press tool.
Note: 9998051
W4088216
29 Lift the range housing away carefully.
Note: Ensure that the range cylinder piston rod does not jam in the transmission housing.
the shaft may then be damaged.
30 Remove the oil distributor pipe using the special tool socket.
Note: 9990027
T4021428
Page
14(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
31 Remove the snap ring securing the high range synchronizer cone.
T4021426
32 Remove both halves of the washer.
T4021427
33 Install both the puller halves onto the high range synchronizer cone.
Note: 88800015
T4021425
Page
15(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
34 Install one half of the puller 9998542 onto the puller rings, together with the hydraulic
cylinder, spindle, and drift.
Note: Ensure that the split in the puller rings is at 90 ° to split the puller.
Note: 88800015, 9992619, 9992671, 9996889, 9998542
T4021429
W4089791
1 – 88800015
2 – Puller Ring
3 – 9998542
4 – 90 ° Position for Tool
5 – Tool Set on Puller Ring
Page
16(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
35 Install the other half of the puller 9998542. Install the hydraulic pump. Press off the high
range synchronizer cone.
Note: 9996222
T4021430
Note: After removing the cone check the part number of the spacer. If the part number is
20533124 then replace the spacer with a new spacer included in the I-Shift Range
Synchronizer Service Kit (part number 85013966).
W4089323
Note: The next three steps are required ONLY if the spacer is replaced.
Page
17(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
36 Remove the rear cover for the main shaft and where applicable oil pipe for overdrive gear.
T4021434
37 Remove the adjustment shim for the main shaft.
W4088866
1 – Shim
2 – Spacer
W4089450
Spacer
Page
18(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
38 Remove the spacer with a suitable tool and replace with the spacer included in the kit.
39 Reinstall the shim.
40 Reinstall the rear cover. Torque fasteners to 40 ± 5 Nm (30 ± 4 ft-lb).
41 Press on the new high range cone.
Note: 88800015, 9992671, 9996222, 9996315, 9998542
W4089452
1 – 9996315
2 – 9992671
3 – 9998542
4 – 9996917
5 – 88800015
6 – 9996222
42 Install both the washer halves.
T4021427
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19(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
43 Install the high range snap ring.
T4021426
Note: Insure a tight fit between the snap ring and the groove. Several different thickness
snap rings have been included in the kit. Use the largest snap ring that will completely seat
in the groove with the least amount of axial movement.
44 Oil and install new O-rings onto the oil distribution piping. Install the oil distribution piping.
Tighten the oil distribution piping to 250 ± 35 Nm (184 ± 26 ft-lb).
Note: 9990027
45 Apply an approved high-temperature liquid gasket to the mating surface of the main
transmission housing.
W4089451
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20(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
46 Position the range housing over the main housing. Lower and line up the piston rod and
planet wheel. Install the fasteners and tighten to 110 ± 10 Nm (81 ± 7.4 ft-lb).
Note: Insert the guide pins 9996876 into the transmission housing to facilitate the
assembly.
Note: 9996876
47 Check that the control housing sealing surface is clean. Install a new control housing
gasket.
Note: When installing a new gasket on a C design level transmission, some gasket
material will protrude from the control housing. Trim excess gasket material.
Note: Clean any dirt and corrosion from the alignment dowels in the housing and from the
dowel holes in the control housing assembly to aid in reinstallation.
W4055781
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
48 Ensure that the split engaging ring is in its rear most position. Ensure that the 2nd/3rd
engaging ring is in neutral or middle position and that the reverse gear engaging ring is in
its rear most position (Figure 1). Also ensure that the range gear is in high range (Figure
2).
Note: Ensure that the new control housing forks correspond to the position of the
engaging rings. If they do not correspond, gently position them by hand.
T4021451
Figure 1
HR – High Range
S – Split
2/3 – 2nd/3rd gear in neutral
R – Reverse gear
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
W4002948
Figure 2
49 Ensure that the range servo piston is positioned out 25.4 mm (1 in.) to properly mate with
the main housing.
W4002950
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23(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
50
CAUTION
Always install the alignment pins before installing the control housing to prevent damage
to the transmission main shaft speed tone ring and the speed sensor.
Install the alignment pins in the transmission.
Note: 9996876
T4018982
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24(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
51
CAUTION
To avoid component damage gently install the control housing with little more than
gentle taps to seat in place. If the control housing does not install easily, remove and
check the alignment of components in the gearbox and the control housing assembly.
Forcing the control housing can cause un-repairable damage and requires a component
replacement.
Carefully lower the control housing to avoid damaging the tooth wheel in the transmission.
Ensure that the split fork ends up in the correct position in engaging ring. Remove the
alignment pins.
W4002949
52 Installed new solenoid valve seals, an O-ring for the counter-shaft brake and a new upper
cover gasket.
Note: Only perform this and the following steps if; the control housing was replace without
a new upper cover. If replacing the control housing as a complete assembly proceed to 55.
T4020778
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
53
CAUTION
Electrical components, including the wiring harness inside the transmission control
housing, are delicate. Handle with extreme care. Failure to do so may result in damage
to components.
Place the new upper cover in position and carefully connect the wiring harness. Lower the
upper cover into position.
Note: Do not apply tension or weight to the wiring harness or connector.
W4002953
54 Install and torque the six upper cover mounting bolts. Torque fasteners to 24 ± 4 Nm (18 ±
3 ft-lb).
W4002952
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
55 Install the control housing. Torque the fasteners to 110 ± 10 Nm (81 ± 7 ft-lb).
W4002951
56 Connect the clutch control valve air supply tube to the upper control housing fitting.
W4002947
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
57 Install the blocking body, spring and plug for the range function.
C4052785
58 Connect the clutch valve wiring connector to the control housing.
W4002881
Page
28(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
59 After the control housing has been installed, use Premium Tech Tool (PTT) to perform
operation 4000-07-04-01 “Transmission Calibration (Transmission Removed)”.
Note: If calibration fails, check that the shift fork position sensor values are within the
specification ranges. Shift fork values out of range may indicate incorrect assembly of shift
forks to engaging rings preventing correct transmission shifting. Remove control housing
and inspect shift fork and engaging ring positions. Repeat the control housing installation.
60 To aid transmission installation, remove the service plug on the clutch control valve
assembly. Clean around the plug prior to removal to prevent debris from entering the
valve. Place a clean shop rag over the open port to prevent debris from entering the valve
during installation. Once the installation is complete replace the plug and torque to 7 ± 2
Nm (5 ± 1 ft-lb).
Note: Failure to perform this step will hamper installation. The transmission will be
installed under clutch cylinder spring pressure and will fail to freely slide forward into place
against the flywheel housing mating surface.
61 Carefully install the transmission and align to the engine. Loosely install two upper and two
lower transmission-to-engine mounting bolts to hold the transmission in place.
Note: The use of an assistant may be necessary to aid during installation.
Note: Rotate the input shaft to align the clutch splines.
T4021203
62 Install the remaining transmission-to-engine mounting bolts. Torque to 92 ± 8 Nm (68 ± 6
ft-lb). Remove the transmission jack.
Note: To aid access, install and tighten the mounting bolts on the top of the clutch housing
first. Remove the transmission jack and install the remaining mounting bolts.
63 Position the battery cables and install their mounting bolts.
64 Install the cab engine cover.
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29(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
65 Position the electrical harness and reconnect the control housing, speed sensor and two
chassis connectors.
W4002941
66 Install new tie straps to secure the wiring harness to the transmission.
67 Connect the air supply hose at the rear of the transmission.
W4002940
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
68 Connect the transmission oil cooler hoses to the filter housing.
W4002894
69 Install the drive shaft, the universal joint caps and the bolts holding the intermediate
bearing to the support bracket if equipped).
Note: It is important to center the rubber insulator in the U-bracket correctly.
* Intermediate Bearing: 105 ± 20 Nm (78 ± 15 ft-lb)
* Universal Joint Caps: 170 ± 15 Nm (125 ± 10 ft-lb)
70 Remove the supporting jack stands and lower the vehicle.
71 Pressurize the air system and check for leaks.
72 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
fasteners to 20 ± 2 Nm (15 ± 1.5 ft-lb).
73 Check and fill the transmission with approved transmission oil.
74 Use Premium Tech Tool to perform a “clutch engagement position calibration”.
Note: If a new transmission control module (TCM) was installed with the control housing,
configure the TCM with its software prior to performing the “clutch engagement position
calibration”.
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Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
Page
32(32)
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
4329–03–09–01 8.4
hrs.
43251–2–00 — 8.4
hrs.
Causal Part
21480996
21480996
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.