NHTSA ID Number: 10126542
Manufacturer Communication Number: FSB 432-013
TSB/Document Date: 2017-12-22
Summary
AMT High Range Cone Replacement
Field Service Bulletin
Trucks
Volvo Trucks
North America
Greensboro, NC USA
Date
4.2014
Group
No.
Release
432 013 01
Page
1(32)
AMT High Range Cone
Replacement
VN, VHD, VAH, VT
FSB 432-013, AMT High Range Cone Replacement
(April 2014)
This document provides the recommended procedure for replacing the high range section of
the Automated Manual Transmission (AMT) including the high range cone.
Service personnel: Please circulate, read and initial
Service
Manager
Warranty
Administrator
PV729-FSB432-013
Workshop
Foreman
Service Technicians
USA63912
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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.
Page
2(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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
Page
3(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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.
Page
4(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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
Page
5(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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
4.2014
Group
No.
Release
432
013
01
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
Page
7(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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
Page
8(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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
Page
9(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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
4.2014
Group
No.
Release
432
013
01
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
Page
11(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
24 Install the spacer flange onto the fixing plate. With the aid of the arm, install the fixing plate
to the transmission. Using an approved lifting device, install the transmission onto the
overhaul stand.
Note: 9986485, 9990031, 9996905, 9999737
T4020968
25
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
Page
12(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
26 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
27 Turn the transmission so that the output shaft flange faces upwards.
28 Remove the plug, spring, and blocking body for the range function.
Note: If necessary, use a magnet to pull out the blocking body.
C4052785
Page
13(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
29 Split the main housing and range housing using the press tool.
Note: 9998051
W4088216
30 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.
31 Remove the oil distributor pipe using the special tool socket.
Note: 9990027
T4021428
Page
14(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
32 Remove the snap ring securing the high range synchronizer cone.
T4021426
33 Remove both halves of the washer.
T4021427
34 Install both the puller halves onto the high range synchronizer cone.
Note: 988800015
T4021425
Page
15(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
35 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
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TSB/Document ID: FSB 432-013
Replacement Service Bulletin Number:
MFR Communication Date: 2014-04-29
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: POWER TRAIN
MFR Component System:
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