NHTSA ID Number: 10126568
Manufacturer Communication Number: FSB 431-010
TSB/Document Date: 2017-12-22
Summary
Range Synchronizer, Repair
Volvo
Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
45 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
W4002948
Figure 2
Page
26(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
46 Ensure that the range servo piston is positioned out 25.4 mm (1 in.) to properly mate with
the main housing.
W4002950
47
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.
T4018982
Page
27(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
48
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 unrepairable 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
Page
28(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
49 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 52.
T4020778
Page
29(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
50
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
Page
30(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
51 Install the six upper cover mounting bolts. Tighten fasteners to 24 ±4 Nm (18 ±3 ft-lb).
W4002952
52 Install the control housing. Tighten the fasteners to 110 ±10 Nm (81 ±7 ft-lb).
W4002951
Page
31(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
53 Connect the clutch control valve air supply tube to the upper control housing fitting.
W4002947
54 Install the plunger, spring and plug for the range function. Tighten plug to 55 ±8 Nm (41 ±6
lb-ft).
55 Connect the clutch valve wiring connector to the control housing.
W4002881
Page
32(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
56 After the control housing has been installed, use PTT to perform calibration operation
4000-07-04-01 “Gearbox (Gearbox 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. Perform tests in PTT to
check Range cylinder (4320-08-03-02), Split cylinder (4320-08-03-03), Gear selector
cylinder 2/3 (4320-08-03-05) and Gear selector cylinder 1/Reverse (4320-08-03-24).
Remove control housing and inspect shift fork and engaging ring positions. Repeat the
control housing installation.
Note: If software needs to be updated, do NOT program gearbox until after all assembly is
complete.
57 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 tighten 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.
58 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: Do NOT lubricate the input shaft splines.
Note: The use of an assistant may be necessary to aid during installation.
Note: Rotate the input shaft to align the clutch splines.
T4021203
Page
33(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
59 Install the remaining transmission-to-engine mounting bolts. Tighten to 92 ±8 Nm (68 ±6 ftlb). 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.
60 Position the battery cables and install their mounting bolts.
61 Position the electrical harness and reconnect the control housing, speed sensor and two
chassis connectors.
W4002941
62 Install new tie straps to secure the wiring harness to the transmission.
63 Connect the air supply hose at the rear of the transmission.
W4002940
Page
34(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
64 Connect the transmission oil cooler hoses to the filter housing.
W4002894
65 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)
66 Remove the supporting jack stands and lower the vehicle.
67 Pressurize the air system and check for leaks.
68 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
fasteners to 20 ±2 Nm (15 ±1.5 ft-lb).
Page
35(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
69 Replace the transmission oil filter.
W4002908
70 Fill the transmission with approved transmission oil.
71 Use PTT to check the transmission electronic control unit (TECU) software, current main
software is 22357273. If the software is not current, program the TECU. From the Main
Menu select Program and then Program Electronic Control Unit 1700-08-03-39. Then click
Start. Select Transmission ECU (TECU). Select Program to update the TECU with the
latest software.
72 Use PTT to perform calibration operation 4320-07-03-01 “Gearbox, clutch, engagement
point”.
73 Clear all diagnostic trouble codes (DTC) prior to returning to service.
Page
36(37)
Volvo Trucks North America
Field Service Bulletin
Date
4.2015
Group
No.
Release
431
010
02
Page
37(37)
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.
Reimbursement
UCHP
Reimbursement
eWarranty
Claim Type (used only when uploading from the Dealer Bus. Sys.)
W
W
Primary Labor Code
4319-16-09-01 —
7.7 hrs.
43106–2–00 — 7.7
hrs.
Causal Part
21480996
21480996
Labor Code
Volvo Trucks North America reserves the right to make any changes in design or to make
additions to or upon its products without incurring any obligations to install the same on
vehicles previously built.
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TSB/Document ID: FSB 431-010
Replacement Service Bulletin Number:
MFR Communication Date: 2015-04-23
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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