K53011517

Solution K53011517
Thursday, April 4, 2019 8:26:16 PM CEST
** SOLUTION **
Title
Volvo Chassis - Automated Manual Transmission ( AMT, I-Shift ) Repair Strategy;
Component Inspection And Reuse Guidelines And Instructions; Required Tasks When
Disassembling An AMT For Repair - For use with Service News SNV19-020e
Volvo Models
VNL , VNM , VNR , VNX , VAH , VHD
Volvo Model
Emission Standard
Emission Standard
US07 , US10 , US10+OBD13 , US14+OBD13 , US14+OBD15 , US14+OBD16 , US
17+OBD16 , US17+OBD18 , US17+OBD19
Engine family
Engine family
11L Engine , 13L Engine , 16L Engine
Transmission
Transmission
AMT-C , AMT-D , AMT-F With Crawler Gears , AMT-F Without Crawler Gears
** SOLUTION **
TMAC and Warranty have been receiving core returns and warranty claims for complete
Cause
transmissions replaced due to failures when only a partial transmission or component
replacement was necessary. This solution provides an explanation of the process for
inspecting the AMT gearbox for suitability for repair to prevent items from being
overlooked and proper repair instructions for relevant findings.
This solution is to be followed when a failure has been identified and transmission
components need to be inspected to determine the viability of repair or replacement.
Soluti
This solution should be used together with SNV19-020e.
on
NOTE: Duplicated or excessive labor charged to a claim due to a component failure that is missed during
initial diagnosis and teardown may be denied by warranty.
Inspection
- Operation 4311-06-02-01 Transmission Reuse or Replacement Guidelines, found under the Service tab in
Impact, should be used for guidance when inspecting the components below. This operation contains very
detailed information on what are and are not acceptable appearances, conditions and specifications for each
component.
- Individual components removed during disassembly for repair should be inspected and replaced as
necessary.
- All major areas of the transmission should be inspected prior to making repair decisions to prevent items
from being overlooked:
Several of the items listed below may already have been inspected during the diagnostic process
• Control Housing Assembly
• Main shaft and countershaft components in the main gearbox
• Input shaft, radial and/or axial play
• Rear of gearbox and range housing assembly
The PTO cover or range housing assembly should be removed as necessary to complete inspection
- If a significant amount of debris is found in the gearbox:
• Remove the range housing assembly
• Remove the lubrication pipe (lube tube) from the main shaft
Check for a buildup of metal flakes inside the main shaft that is also visible in the lubrication pipe
and on the o-rings.
- If this condition is observed the main box and oil cooler must be replaced.
- NOTE: A loose or failed high range synchronizer cone does not automatically warrant replacement of the
complete synchronizer assembly or range housing if the short gearbox is being replaced.
Repair
AS OF 26 MARCH 2019: Per SNV19-020e an eService case
is required prior to utilizing any of the information below.
The eService case MUST INCLUDE a THOROUGH
description of the initial symptoms AND findings from the
Inspection section.
The charts below outline the correct repair path for the most AMT issues encountered. Once the failure is
identified, refer to the correct description at the top of each chart for the proper components that should be
used for each repair. If the secondary (yellow) option needs to be used due to progressive damage or parts
availability, eService will advise on how to proceed.
- Green - Denotes the typical repair for the given failure. This option should be considered first.
- Yellow - Denotes the secondary option if progressive (additional) damage is found upon inspection or if
there are issues with parts availability
• NOTE: Tech support should be contacted via eService for further review if a secondary option is
required due to parts availability ONLY.
Pictures and descriptions of common replacement parts can be found below:
Basic Transmission
- Same as complete, but
does not include the CCA,
TECU, or Top Cover
Assembly & Solenoid
Short Transmission
Same as Basic, but without
Range Shift Assembly
Range Housing
Assembly
Internal comments (FO)
SAVED FOR FUTURE USE:
The only time pre-authorization and an eService case is required is when:
- Diagnostics at the dealership level determines that a Complete or Basic
Reman, or a New Complete Transmission is required.
- A new vehicle with low mileage (less than 50,000 mi, 80,000 km) experiences an
internal Transmission failure that may be a candidate for a New assembly as opposed
to Reman.
- A secondary repair option is required due to parts availability (See Repair section
below)
- All diagnostic options and materials have been exhausted without the root cause
identified, and additional support is needed
All other repairs to the transmission—including replacing a section of the
transmission—DO NOT require an eService case or authorization.
Internal comments (BO)
Warranty
The only time pre-authorization and an eService case is required is when:
- A new vehicle with low mileage (less than 50,000 mi, 80,000 km) experiences an
internal Transmission failure that may be a candidate for a New assembly as opposed
to Reman.
- A Complete Transmission has to be replaced (New OR Reman)
- A secondary repair option is required due to parts availability (See Repair section
above)
- All diagnostic options and materials have been exhausted without the root cause
identified, and additional support is needed
All other repairs to the transmission—including replacing a section of the
transmission—DO NOT require an eService case or authorization.
For any other questions or additional information, refer to the Warranty Operations
Manual, which can be found on Trucks Dealer Portal (TDP).
Warranty Claim Submission
- The following Standalone Items will be allowed on the same claim line:
• Short Transmission
• Basic Transmission
• Control Housing
• Range Housing
- The Add-on Items below may be combined with the Standalone Components above, if
justified by the extent of the failure:
• Transmission Oil Cooler
• Internal (Ribbon) Harness Kit
• Gaskets and/or Seals
• Transmission Oil
Refer to SNV17-05 I-Shift Lubricant on Warranty Claims for more information.
- The Items below should be filed on another claim line if discovered during an AMT
Repair:
• Flywheel
• Clutch Control Actuator (CCA)
• Clutch Control Valve (CCV)
• Clutch Kit
Labor Codes
- Short Transmission
• 1700-16-01-01 Take Charge
• 1700-16-03-01 Diagnostic Time
• 4311-03-02-06 Transmission, Replacement
• 1700-20-09-01 Road Test
- Basic Transmission
• 1700-16-01-01 Take Charge
• 1700-16-03-01 Diagnostic Time
• 4311-03-02-05 Transmission, Replacement (Basic)
• 1700-20-09-01 Road Test
- Range Assembly
• 1700-16-01-01 Take Charge
• 1700-16-03-01 Diagnostic Time
• 4315-03-02-02 Range Synchronizer, Replacement
• 4319-04-02-01 Range Cylinder, Overhaul
• 1700-20-09-01 Road Test
- Control Housing
• 1700-16-01-01 Take Charge
• 1700-16-03-01 Diagnostic Time
• 4329-03-02-38 Control Housing, Replacement
• 1700-20-09-01 Road Test
- Transmission Electronic Control Unit (TECU)
• 1700-16-01-01 Take Charge
• 1700-16-03-01 Diagnostic Time
• 4319-03-02-03 Transmission ECU, Replacement
• 1700-20-09-01 Road Test
NA_Sister solutions
K45673535
Campaign code
SNV19-020e
Solution visibility
Dealer distribution
Function(s)/component(s) affected
Function affected
Transmission , Diagnostic tool , SNV
Function Group
Function Group
43 gearbox , 47 gearbox and reverse gear (or forward gear) combined system
Customer effect
Main customer effect
diagnostics/methodology , judder , slipping
Visual appearance
wear , crack/fracture , part lost/missing function
Conditions
Vehicle operating mode
Frequency of occurrence of
problem
Gear ratio
Administration
when driving , when stationary , engagement
random
upshifting , downshifting , reverse gear
Author
RU4469V
Dealer ID
RU4469V
Last modified by
RU4469V
Creation date
22-03-2018 20:03
Date of last update
01-04-2019 14:04
Review date
15-07-2018 00:07
Status
Published
Variantes Kola
RWX - TRANSMISSION
AT2412D - VPT AUTOMATED TRANSMISSION 2400NM 12SPEED , AT2612D VPT AUTOMATED TRANSMISSION 2600NM 12SPEED , ATO2612D , ATO3112D
- VPT AUTOMATED TRANSMISSION 3100NM OVERDRIVE 12SPEED , AT2812D
- VOLVO AUTOMATED TRANSMISSION 2800NM 12SPEED , ATO8006 - AMT
800NM 6 SPEED (AUTOMATED MECHANICAL TRANSMISSION) , ATO1056 AMT 1050NM 6 SPEED (AUTOMATED MECHANICAL TRANSMISSION) , ATO1
212 - AMT 1200NM 12 SPEED (AUTOMATED MECHANICAL TRANSMISSION) ,
AT2412F - VPT AUTOMATED TRANSMISSION 2400NM 12SPEED , AT2612F VPT AUTOMATED TRANSMISSION 2600NM 12SPEED , ATO2612F - VPT
AUTOMATED TRANSMISSION 2600NM OVERDRIVE , AT2412C - VOLVO
AUTOMATED TRANSMISSION 2400NM , AT2512C - VOLVO AUTOMATED
TRANSMISSION 2500NM (1850 LB FT) , ATO2512C - VOLVO AUTOMATED
TRANSMISSION 2500NM (1850 LB FT) OVERDRIVE , AT2812C - VOLVO
AUTOMATED TRANSMISSION 2800NM (2050 LB FT)