NHTSA ID Number: 10126542
Manufacturer Communication Number: FSB 432-013
TSB/Document Date: 2017-12-22
Summary
AMT High Range Cone Replacement
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
4.2014
Group
No.
Release
432
013
01
36 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 kit (part number
21695754 or 21339270).
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
4.2014
Group
No.
Release
432
013
01
37 Remove the rear cover for the main shaft and where applicable oil pipe for overdrive gear.
T4021434
38 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
4.2014
Group
No.
Release
432
013
01
39 Remove the spacer with a suitable tool and replace with the spacer included in the kit.
40 Reinstall the shim.
41 Reinstall the rear cover. Torque fasteners to 40 ± 5 Nm (30 ± 4 ft-lb).
42 Press on the new high range cone.
Note: 88800015, 9992671, 9996081, 9996222, 9996315, 9998542
W4089452
1 – 9996315
2 – 9992671
3 – 9998542
4 – 9996917
5 – 88800015
6 – 9996222
43 Install both the washer halves.
T4021427
Page
19(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
44 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.
45 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
46 Apply an approved high-temperature liquid gasket to the mating surface of the main
transmission housing.
W4089451
Page
20(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
47 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
48 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
Page
21(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
49 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
Page
22(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
W4002948
Figure 2
50 Ensure that the range servo piston is positioned out 25.4 mm (1 in.) to properly mate with
the main housing.
W4002950
Page
23(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
51
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
Page
24(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
52
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
53 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 56.
T4020778
Page
25(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
54
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
55 Install and torque the six upper cover mounting bolts. Torque fasteners to 24 ± 4 Nm (18 ±
3 ft-lb).
W4002952
Page
26(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
56 Install the control housing. Torque the fasteners to 110 ± 10 Nm (81 ± 7 ft-lb).
W4002951
57 Connect the clutch control valve air supply tube to the upper control housing fitting.
W4002947
Page
27(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
58 Install the blocking body, spring and plug for the range function.
C4052785
59 Connect the clutch valve wiring connector to the control housing.
W4002881
Page
28(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
60 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.
61 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.
62 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
63 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.
64 Position the battery cables and install their mounting bolts.
65 Install the cab engine cover.
Page
29(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
66 Position the electrical harness and reconnect the control housing, speed sensor and two
chassis connectors.
W4002941
67 Install new tie straps to secure the wiring harness to the transmission.
68 Connect the air supply hose at the rear of the transmission.
W4002940
Page
30(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
69 Connect the transmission oil cooler hoses to the filter housing.
W4002894
70 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)
71 Remove the supporting jack stands and lower the vehicle.
72 Pressurize the air system and check for leaks.
73 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
fasteners to 20 ± 2 Nm (15 ± 1.5 ft-lb).
74 Check and fill the transmission with approved transmission oil.
75 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”.
Page
31(32)
Volvo Trucks North America
Field Service Bulletin
Date
4.2014
Group
No.
Release
432
013
01
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.
Claim Type (used only when uploading from the Dealer Bus. Sys.)
W
Labor Code
Primary Labor Code
43251–2–00
8.4 hrs.
Causal Part
21480996
Volvo Trucks North America engages in a continuous program of testing and evaluating to
provide the best possible product. Volvo Trucks North America, however, is not committed to,
or liable for updating existing chassis.
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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:
MFR Component Subsystem:
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