NHTSA ID Number: 10126633
Manufacturer Communication Number: FSB 216-001
TSB/Document Date: 2017-12-22
Summary
Twin Mass Flywheel Conversion, Transmission Removed
No.
Release
216
001
02
22 To align the flywheel to the crankshaft, lift on the flywheel with the aid of the 2 bolts
(M10x100 mm). Screw in the mounting bolts.
W2091562
23 Use a drift to align the bolt holes. Install all the flywheel fasteners.
Page
11(20)
Volvo Trucks
North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
24 To hold the flywheel in position, install the rotation tool (Tool Number 88800014 or
88840317).
W4088532
A – Rotation Tool
25 Torque the flywheel fasteners in sequence. Torque fasteners to 60 ± 5 Nm (44 ± 4 ft-lb).
Torque each fastener in sequence an additional 120 ± 10 degrees.
W4088533
Page
12(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
26 Remove the rotation tool. Install the plug.
W4088534
27 Install the engine speed sensor. Torque fastener to 8 ± 2 Nm (6 ± 1.5 ft-lb).
Note: Install a new O-ring when reinstalling the engine speed sensor
W4088527
Page
13(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
28 Reconnect the engine speed sensor.
W4088525
29 Install special tools (Tool Numbers 9991801 [B] and 9992564 [A]). Install the pilot bearing
into the flywheel.
W4088535
A – Mandrel
B – Handle
Page
14(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
30 Install the new clutch disc.
W4088524
31 Install new pressure plate.
Note: Install the clutch disc and pressure plate together.
W4088520
A – Fixture (Tool Number 9996857)
B – Retainer (Tool Number 9996896)
C – Support (Tool Number 9996996)
Page
15(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
32
CAUTION
If the pressure plate fasteners are torqued out of sequence distortion damage can occur.
Torque pressure plate fasteners in sequence to 53 ± 5 Nm (39 ± 4 ft-lb).
W4088519
A – Clutch Alignment Tool
33 Remove the clutch release bearing hose zip ties.
W4088540
Page
16(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
34 Remove the clutch release bearing hose.
W4088541
35 Remove the clutch cylinder.
W4088542
Page
17(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
36 Install the spacer disc.
W4088543
37 Install the new clutch cylinder with the longer mounting fasteners included in the kit.
Torque fasteners to 45 ± 5 Nm (33 ± 4 ft-lb).
38 Check the clutch release bearing hose O-rings for damage. Replace the O-rings (part
number 22485772), if necessary.
W4088544
Page
18(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
39 Install the clutch release bearing hose. Install cable ties to secure the hose into position.
W4088541
40 Install the transmission. Refer to Function Group 43.
41 Connect all previously removed cables to the negative (ground) battery terminals. Tighten
fasteners to 20 ± 2 Nm (15 ± 1.5 ft-lb).
42 Using Premium Tech Tool run conversion kit(s) as listed below::
Note: Once the hardware conversion has been completed, run Conversion Kit 85142350
only for US07 and EM-USA10 vehicles. For EOBD-2013 and EM-USA14 vehicles, run
Conversion Kit 1 and Conversion Kit 2 in order.
Vehicle
Conversion Kit 1
Conversion Kit 2
VN, VT, US07, ATO3112C,
ATO3112D
Not Applicable
85142350
VN, EM-USA10
Not Applicable
85142350
VN, EOBD-2013
85142351
85142352
VN, EM-USA14
85142351
85142352
43 Use PTT to program the transmission electronic control unit (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.
44 When programing is complete, select Calibrate from the Main Menu. Select 4320-07-0301 Gearbox, clutch, engagement point.
45 When Calibration is complete, clear any diagnostic trouble codes (DTC) and Finish Work.
Page
19(20)
Volvo Trucks North America
Field Service Bulletin
Date
1.2015
Group
No.
Release
216
001
02
Page
20(20)
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
2160-03-09-01 —
1.7 hrs.
21618–2–00 — 1.7
hrs.
Causal Part
21905650
21905650
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 216-001
Replacement Service Bulletin Number:
MFR Communication Date: 2015-01-13
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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