KC-183 Service Bulletin/Repair Instructions

11/30/2020
Content creation stages KC-183
Volvo Chassis - ( AMT, I-Shift ) - Transmission

Grinding When Downshifting ; Range

Synchronizer (Synchro) Timing Procedure - US07

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FSB 431-010
Internal Content
Repair information was released with FSB 431-010 Range

Synchronizer, Repair and can be found in Impact.

1. Navigate to the Service tab.

2. In the Additional Search Values box, make sure Titles is selected in the

top box.

3. Enter 431-010 into the text entry box, press the Search button.

4. A link for the bulletin will be shown in the results. Click on the title,

then choose one of the options from the window that opens.

NOTE: The symptoms and issue described in this solution can apply to

AMT models other than AMT-D. If a vehicle presents the same

symptoms the FSB should be used as part of diagnosis.
a
Tags
K81654757
AMT-C
AMT-D
AMT-F WITH CRAWLER GEARS

AMT-F WITHOUT CRAWLER GEARS
GRINDING
FSB 431-010
Feedback

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11/30/2020
Content creation stages KC-183
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FSB 431-010, Range Synchronizer, Repair

(October 2017)

This procedure is to repair mDrive transmissions in the field that exhibit a grinding noise when the transmission range

shifts (for example: between 6th and 7th gear) built between 01/01/2013 and 08/18/2014.
Required Parts

I-Shift Range Synchronizer Repair Kit, Part Number 85020354

TECU main software equal to or greater than 23084204
Optional Parts

Note: The assembly should be disassembled and inspected before ordering optional parts.

Range Shift Fork, Part Number 21510395

Set Screws, Part Number 1652847
Required Tools

Special tools: 9809726, 9990027, 9992619, 9992671, 9992884, 9996315, 9996876, 9996889, 9996917, 9998051,

9998542, 85108826, 88800015

Premium Tech Tool version 2.06.20 or higher

Vocom Diagnostic Connector 88890304 or 88890253

Communication Interface 88890300
Note: Using other interfaces may affect programming speed.

Note: Check Premium Tech Tool version by clicking on Help tab and then click on “About Tech Tool”.
Failed Parts
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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The synchronizer ring is missing the high range friction material and the low range side is wearing away.
Procedure
You must read and understand the precautions and guidelines in Service Information, Function 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: 9809726, 9990027, 9992619, 9992671, 9992884, 9996315, 9996876, 9996889, 9996917,

9998051, 9998542, 85108826, 88800015

1. Use Premium Tech Tool (PTT) to perform operation 4000-08-03-11 Gear activation, control housing (for removal

/replacement). Follow the instructions in PTT.
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.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
2.
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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.

6. Drain the transmission oil into a suitable container.
Warning

Hot transmission oil can cause burns. DO NOT allow hot transmission oil to contact the skin. When changing

transmission oil, wear protective gloves.
Caution

Always dispose of lubricants (engine oil, coolant, transmission oil, etc.) and filters according to Federal or local

regulations. Dumping used oil or coolant on the ground or in waterways can contaminate our drinking water and

kill wildlife.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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7. Remove the transmission. Refer to Function Group 431.

8. Remove the control housing mounting bolts.
9. Remove the six TECU mounting bolts.
Note: It is only necessary to perform this step if manually performing the Gear activation, control housing (for removal

/replacement). If PTT activated the necessary gears, proceed to step 1.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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10. 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.
11.
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.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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12. 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
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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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
Note: For direct drive transmissions, the transmission must be positioned as follows:

* High Split

* High Range

* 2nd/3rd — Neutral Position

* 1st/Reverse — Reverse Position
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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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
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.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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13.
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 11 or Step 12 before attempting control housing removal again.

Note: Exercise care during removal to keep from damaging the tooth wheel in the transmission.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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14. Remove the plug, spring and plunger for the range function. If necessary use a magnet to pull out the plunger.
15. Remove the range housing mounting fasteners.

16. Use press tool to separate the main housing and range housing.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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1. 9998051

17. Carefully lift the range housing away from the main housing.
Caution

Ensure that the range cylinder piston rod does not jam in the main housing. Damage to the shaft may result.

18. Remove the range gear fasteners.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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19. Mark the orientation of the fork shaft to the synchronizer ring. Remove the range gear.
Note: Gear must be in high range for removal. If difficult to remove, lift on the shaft and tap down on the housing with a

dead blow hammer.
20. Remove the selector fork. Check the brass shifter pads. If the brass shifter pads are damaged or worn, replace the

fork. Tighten the set screws to 75 ±7 Nm (55 ±5 lb-ft) and stake set screws.
Note: After staking, set screws are one time use only.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
13 / 38
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The fork should be replaced if there is this type of damage.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
14 / 38
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Properly Staked Set Screws

21. Remove the oil return pipe.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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22. Remove the retaining ring.
23. Remove the washer.
24. Install the puller rings.
25. Install one half of the puller on puller rings together with the hydraulic cylinder, spindle and drift.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
16 / 38
25.
IMPACT 4.07.82
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Note: Check that the divide in the puller rings is at 90° to the divide in the puller.
1. 88800015

2. Puller Ring

3. 9998542

4. 90° Position for Tool

5. Tool Set on Puller Ring

26. Install the other half of the puller and the hydraulic pump. Remove the high range engaging ring.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by

the Volvo Group

The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.
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