NHTSA ID Number: 10126653
Manufacturer Communication Number: FSB 432-013
TSB/Document Date: 2017-12-22
Summary
AMT High Range Cone Replacement
Group
No.
Release
432
013
02
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
5.2014
Group
No.
Release
432
013
02
24
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
25 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
Page
12(32)
Volvo
Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
26 Turn the transmission so that the output shaft flange faces upwards.
27 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
5.2014
Group
No.
Release
432
013
02
28 Split the main housing and range housing using the press tool.
Note: 9998051
W4088216
29 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.
30 Remove the oil distributor pipe using the special tool socket.
Note: 9990027
T4021428
Page
14(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
31 Remove the snap ring securing the high range synchronizer cone.
T4021426
32 Remove both halves of the washer.
T4021427
33 Install both the puller halves onto the high range synchronizer cone.
Note: 88800015
T4021425
Page
15(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
34 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
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
5.2014
Group
No.
Release
432
013
02
35 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 I-Shift Range
Synchronizer Service Kit (part number 85013966).
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
5.2014
Group
No.
Release
432
013
02
36 Remove the rear cover for the main shaft and where applicable oil pipe for overdrive gear.
T4021434
37 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
5.2014
Group
No.
Release
432
013
02
38 Remove the spacer with a suitable tool and replace with the spacer included in the kit.
39 Reinstall the shim.
40 Reinstall the rear cover. Torque fasteners to 40 ± 5 Nm (30 ± 4 ft-lb).
41 Press on the new high range cone.
Note: 88800015, 9992671, 9996222, 9996315, 9998542
W4089452
1 – 9996315
2 – 9992671
3 – 9998542
4 – 9996917
5 – 88800015
6 – 9996222
42 Install both the washer halves.
T4021427
Page
19(32)
Volvo Trucks North America
Field Service Bulletin
Date
5.2014
Group
No.
Release
432
013
02
43 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.
44 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
45 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
5.2014
Group
No.
Release
432
013
02
46 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
47 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
5.2014
Group
No.
Release
432
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TSB/Document ID: FSB 432-013
Replacement Service Bulletin Number:
MFR Communication Date: 2014-05-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
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