NHTSA ID Number: 10044346
Manufacturer Communication Number: SP-491-030
TSB/Document Date: 2012-06-14
Summary
VOLVO TRUCKS
: THE O RINGS WERE INSTALLED ON TRANSMISSIONS INCORRECTLY AT TIME OF ASSEMBLY, CAUSING TRANSMISSION FLUID LOSS AND/OR DAMAGE TO TRANSMISSION, PREMATURELY. *PE UPDATED 8/21/12. *PE
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TSB/Document ID: SP-491-030
Replacement Service Bulletin Number: SP-491-030-2
MFR Communication Date: 2012-06-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT ADAPTIVE/MOBILITY
MFR Component System:
MFR Component Subsystem:
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SB-10044346-1210
Volvo Trucks North America
Greensboro, NC USA
Service Program
Trucks
Date
Group
No.
Release
Page
5.2012
491
030
01
1( 7 )
Transmission Cooler Line O-Ring
VN, VHD, VAH
SP 491-030, Transmission Cooler Line O-Ring
(MAY 2012)
Certain VOLVO trucks built between January 01, 2012 and March 05, 2012 may have
been assembled with an incorrect o-ring installed on the transmission cooler line fittings.
The transmission cooler line fittings are located at the bottom of the radiator where the
transmission cooler lines connect to the transmission cooler, and where the lines connect
to the transmission. The incorrect o-ring may not seal properly, causing transmission fluid
loss and/or premature transmission damage.
Trucks built after March 05, 2012 were assembled with a replacement o-ring on the
transmission cooler line fittings. A white dot on the shoulder of the fitting cap indicates a
replacement o-ring was installed during assembly. See figure below. Visually inspect the
truck for a white dot on the shoulder of the fitting cap. If the white dot is visible, only an
inspection for the white dot is required. If the white dot is not visible on the fitting cap,
replace the existing o-ring with a new green o-ring (part number 21866819). See the o-ring
replacement procedure on page 2.
W4072905
Transmission Cooler Line Fitting Components
PV729-SP491-030
Item #
Part Number
Description
1
21866819
2
85129501
Locking Collar
3
85131659
Cap
4
N/A
Visual Inspection Mark (White Dot)
USA53209
Volvo Trucks North America
Service Program
Date
5.2012
Group
No.
Release
491
030
01
Procedure
You must read and understand the precautions and guidelines in Service Information,
group 40, "General Safety Practices, Engine" before performing this procedure. If you
are not properly trained and certified in this procedure, ask your supervisor for training
before you perform it.
1 Apply parking brake and place shift lever in neutral.
2 Raise hood.
3 Disconnect all cables from the negative (ground) battery terminals to prevent personal
injury from electrical shock and prevent damage to electrical components.
4 Inspect the transmission cooler line fittings cap for the white dot at the transmission
and the radiator.
Note: If a White Dot is visible on the cap, the inspection is complete. If the White Dot is
not visible on the cap, continue onto step 5.
W4072906
5 Using a screwdriver or suitable instrument, remove the Sure-Fit clip (part number
20733354).
W4072907
Page
2( 7 )
Volvo Trucks North America
Service Program
Date
5.2012
Group
No.
Release
491
030
01
6 Using a screwdriver or suitable instrument, disengage the cap.
W4072908
7 Pull the cap back until it rests against the stop shoulder as shown in the figure below.
W4072909
Page
3( 7 )
Volvo Trucks North America
Service Program
Date
5.2012
Group
No.
Release
491
030
01
8 Locate the 15 mm (0.6 in) transmission line removal tool (part number 85108826) around
the protruding plastic lugs of the locking collar.
Note: Ensure that the internal shoulders of the tool are nearest to the female cavity
face and flat and/or parallel to it.
W4072910
9 Using one hand close the tool jaws around the protruding plastic lugs, compress the
plastic lugs, pull back on the fitting with the other hand, and disconnect the transmission
cooler line fitting.
W4072911
Page
4( 7 )
Volvo Trucks North America
Service Program
Date
5.2012
Group
No.
Release
491
030
01
10 Release the transmission line removal tool and store for future use.
11 Clean both the male and female transmission cooler line fittings of any debris or corrosion.
12 Remove the existing o-ring.
13 Install new green o-ring (part number 21866819).
Note: Lubricate the new o-ring with transmission fluid before installation to prevent
binding when the hose is reinserted into the fitting.
W4072912
14 Ensure that the cap is retracted all the way back to the stop shoulder.
Note: Prior to assembly, be sure that all surfaces are clean to ensure proper connection.
W4072913
15 While holding the transmission cooler line, connect the fitting and push until the locking
collar snaps into position.
W4072914
Page
5( 7 )
Volvo Trucks North America
Service Program
Date
5.2012
Group
No.
Release
491
030
01
16 Slide the cap forward until it snaps onto the protruding lugs of the locking collar.
Note: To ensure a good connection, the cap must be flush with the front face of the
female cavity and no part of the locking collar is visible.
W4072915
17 Install the Sure-Fit clip as shown in the figure below.
Note: If there is difficulty installing the Sure-Fit clip, inspect the transmission cooler
line for a good connection.
W4072916
18 Reconnect all previously removed cables to the negative (ground) battery terminals.
19 Lower hood.
Page
6( 7 )
Volvo Trucks North America
Service Program
Date
5.2012
Group
No.
Release
491
030
01
Reimbursement
This repair is covered by an authorized Service Program. Reimbursement is
obtained through the normal claim handling process.
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
Time for inspection.
49114-0-01
0.3 hrs.
Primary Labor Code
Time for inspection and replacement of the o-ring.
49114-0-02
0.4 hrs.
Time to take charge and determine campaign status
17003–0–01
0.3 hr.
Causal Part
20787860
Authorization Number
SP491–030
Expiration Date
11-MAY-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.
Page
7( 7 )
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