Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

25 Remove debris from hole with magnetic end of Go/No Go depth gauge. Use opposite
end of Go/No Go depth gauge (double marks outward) to check hole depth (white mark
on depth gauge). Repeat drilling if not within minimum depth.
26 Chuck 1/4 inch Letter-C drill bit provided in Consumable kit into high speed drill. Use
Go/No Go depth gauge to confirm drill protrusion is 81 mm (3.19 in) from collar to drill
shoulder (yellow mark on depth gauge). Make sure drill stop screws are tightened
securely.

CAUTION
The drill stop must be positioned correctly. If drill stop is not positioned correctly,
severe damage to engine can result.
Note: The drill stops are pre-assembled with Loctite® to 1/4 inch drill bits. If the drill
stop is not positioned correctly, use heat to break the Loctite® loose and reinstall drill
stop to correct depth.

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Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

Page
13(23)

27 Lubricate drill bit tip with oil. Use light pressure to drill dowel pin hole until contact with
drill stop is made. It is critical to use light drilling pressure to allow bit to cut and not be
forced. Otherwise, drill will walk and result in an inaccurate hole position. Clean drill
flutes frequently by pulling drill back until bit is clear of fixture and then continue cutting.
Repeat as required. Chips should clear freely out of rotating flutes. If chips are becoming
packed in flutes, perform cleaning procedure more frequently.

WARNING
When drilling always wear proper eye protection. Failure to wear proper eye protection can result in serious personal injury.

1. Magnetic End of Go/No Go Depth Gauge
28 Remove debris from hole with magnetic end of Go/No Go depth gauge. Use opposite
end of Go/No Go depth gauge (double marks outward) to check hole depth (yellow mark
on depth gauge). Repeat drilling if not within minimum depth.

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

Page
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29 Chuck 0.248 x 6 inch straight flute reamer provided in Fixture kit in drill. Ream hole with
very light pressure as one continuous pass until reamer reaches bottom of hole. Stop
reaming after reaching bottom of hole.

WARNING
When drilling always wear proper eye protection. Failure to wear proper eye protection can result in serious personal injury.

Straight Flute Reamer
30 Remove debris from hole with magnetic end of Go/No Go depth gauge. Use opposite
end of Go/No Go depth gauge (double marks outward) to check hole depth (yellow
mark on depth gauge).

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

31 Use chip vacuum to clean area around 1/4 inch dowel pin hole drill fixture. Remove fixture
and remove all particles from fixture and barrel. Use brake clean to clean barrel bore.
Check that barrel slides freely in fixture. Use magnetic end of Go/No Go depth gauge to
clean any metal chips or fuzz from gear nut and hub. Use Letter-C drill bit to line up barrel
and reinstall dowel pin hole drill fixture and fasten using speed sensor bolt. Tighten to 8
±2 Nm (72 ±12 in-lb). Adjust drill fixture barrel until contact with hub is felt. Tighten screw
to lock barrel in place, do not overtighten. Use a shop towel to cover gap between drill
guide tube and flywheel housing access hole to prevent any debris from entering engine.

CAUTION
The drill fixture must be properly adjusted for contact against hub. This is critical to
drilling operation. If fixture is not properly adjusted, significant metal debris can enter
engine and cause potential damage including engine failure.

CAUTION
The magnet at the end of the drill fixture barrel is brittle and can break or shatter if tool
is dropped or impacted.

Page
15(23)

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

Page
16(23)

32 Use straw to spray brake cleaner into bottom of dowel pin hole. Use light shop air to
remove excess fluid in dowel pin hole. Vacuum away any remaining debris from flywheel
housing.

WARNING
When spraying brake cleaner into dowel pin hole, be wary of blow-back. Always wear proper eye protection to prevent
serious injury.

CAUTION
Only use shop air to remove excess fluid. Do not use shop air to blow debris as it could
introduce foreign matter into engine and cause serious engine damage.
33 Liberally apply Loctite® retaining compound RC638 provided in Consumable kit to 0.25
x 1.25 inch steel dowel pin provided in Consumable kit. Do NOT apply primer to pin at
any point.

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

34 Slide dowel pin into drill guide and immediately set pin with dowel pin driver provided in
Fixture kit. Drive dowel pin until it bottoms in hole, detectable by a noted change in the
“feel” and “sound” as pin is driven. Use Go/No Go depth gauge to check pin depth (red
mark on depth gauge).
Note: Dowel pin protrusion from hub is normal.

Dowel Pin Driver

Page
17(23)

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

35 Loosen screw and move drill fixture barrel outward as far as possible. Remove drill fixture
quickly and cover crankshaft speed sensor hole. Use brake cleaner to thoroughly clean
flywheel housing drill hole. Use light shop air to remove excess fluid in flywheel housing
hole. Clean drill fixture to remove any retaining compound residue.

Page
18(23)

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

36 Apply Loctite® 7649 primer provided in Consumable kit 360° around outer diameter of
5/8 inch stainless steel cup plug provided in Consumable kit and 360° around inner
diameter of flywheel access hole and let rest for 5 minutes.

Page
19(23)

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

37 Apply Loctite® RC638 retaining compound provided in Consumable kit 360° around outer
diameter of cup plug and 360° around inner diameter of flywheel access hole.

Page
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Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

38 Use 5/8 inch cup plug driver provided in Fixture kit to drive cup plug into access hole
until driver is flush with flywheel housing.

CAUTION
Wait 30 minutes before starting engine to allow Loctite® retaining compound to dry. If
the Loctite® retaining compound does not dry properly, the cup plug may not remain
in the flywheel housing.

Cup Plug Driver

Page
21(23)

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

39 Use new sensor O-ring (part number 20966752) provided in Consumable kit to install
crankshaft speed sensor. Install retainer screw and tighten to 8 ±2 Nm (72 ±12 in-lb).
Connect the speed sensor harness to the sensor.
40 Use new O-ring (part number 1547252) provided in Consumable kit and connect coolant
lines at rear of engine. Cable tie applicable harnesses.
41 Install clamp and bracket securing air compressor discharge line.
42 Install overslung crossmember. Tighten fasteners to 200 ±33 Nm (148 ±24 ft-lb).
43 Use coolant extractor (DBT2V700 or 85112740) to fill the system with saved coolant.
44 Connect the battery cables.
45 After 30 minutes to allow Loctite® to dry, run engine for 10 minutes at 1000 rpm and
check for leaks around the cup plug. After shutdown, replenish fluids as necessary.
46 Install transmission access plate and floor covering.
47 Install the engine cover in the cab.
48 Install the passenger seat in the cab. Tighten mounting fasteners to 48 ±8 Nm (35 ±6 ft-lb).

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22(23)

Volvo Trucks North America
Service Program

Date
5.2012

Group

No.

Release

215

017

01

Reimbursement
This repair is covered by an authorized Service Program. Reimbursement is
obtained via the normal claim handling process. The Consumable Kits are
furnished at no charge. A $50.00 part handling fee can be claimed using Other
Materials on the eWarranty claim, see format below.
Claim Type (used only when uploading from the Dealer Bus.
Sys.)

B

Recall Status
Vehicle inspected, repair not required

1- Inspected OK

Vehicle repaired per instruction

2- Modified per
instruction

Labor Code
Primary Labor Code

21528-0-02 — 4.7
hrs.

Time to take charge and determine campaign status

17003–0–01 —
0.3 hrs.

Causal Part

21760930

Other Materials
Handling fee

$50.00

Parts Disposition
Authorization Number

SP215017

Expiration Date

30–Jun–13

Note: Take Charge Time is not included in the Labor Code for this operation. Take charge
may be eligible but can only be used once per repair visit. If vehicle is having other warranty
repairs performed, take charge should be charged to the warranty repair, otherwise take
charge can be charged to this service program.

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