NHTSA ID Number: 10183339
Manufacturer Communication Number: KC-183
TSB/Document Date: 2020-12-01
Summary
Volvo Chassis - ( AMT, I-Shift ) - Transmission Grinding When Downshifting ; Range Synchronizer (Synchro) Timing Procedure - US07 And Newer
27. Clean and inspect all components.
Note: The synchronizing ring (B) must not be washed.
28. 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.
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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Note: The next four steps are required ONLY if the spacer is replaced.
29. Remove the rear cover for the main shaft and where applicable oil pipe for overdrive gear.
30. Remove the adjustment shim for the main shaft.
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. Shim
2. Spacer
Spacer
31. Remove the spacer with a suitable tool and replace with the spacer included in the kit.
32. Reinstall the shim and the rear cover. Tighten fasteners to 48 ±5 Nm (35 ±4 ft-lb).
33. Press in a new 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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1. 9996315
2. 9992671
3. 9998542
4. 9996917
5. 88800015
6. 9809726
7. 9992884
34. Install both washer halves.
35. Install the retaining ring from the kit.
Note: There are several rings in the kit. Install the thickest ring that will seat correctly in the groove.
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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36. Oil and install O-rings. Install the oil return pipe. Tighten to 250 ±50 Nm (184 ±37 lb-ft).
37. Clean old sealant off the range housing.
38. Lubricate sliding surfaces and O-rings with transmission fluid during assembly. It is important to lubricate the carbon
fiber lining on synchronizing ring (B).
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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39. Lubricate the short end of the shaft before installation. Install the engaging ring and selector fork on the ring gear. Use
the orientation mark to properly align new 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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40. To ensure correct operation, it is important that wide tooth (D) on the synchronizing ring (C) line up with a chamfered
(angled) tooth (A) on the ring gear (B) as illustrated below.
41. Use the inspection guide in the figure below to ensure proper assembly before installation of the package into the
range housing.
Note: Improper assembly of these components will cause gear clash on range downshifts.
Package Inspection Guide
Notice the wide tooth of the synchronizing ring is next to the chamfered (angled) tooth of
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 gear ring.
The wide tooth of the synchronizing ring is not next to the chamfered (angled) tooth of
the ring gear.
42. Install the package in the range housing. Tighten the fasteners diagonally to 110 ±10 Nm (81 ±7 lb-ft).
43. Apply a bead of approved sealant to the housing face as shown.
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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44. Line up the piston rod and planetary gear. Carefully lower the range housing into the main housing.
45. Install the range housing mounting fasteners. Tighten fasteners to 110 ±10 Nm (81 ±7 lb-ft).
46. Check that the control housing sealing surface is clean. Install a new control housing gasket.
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.
47. 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.
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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Figure 1
HR – High Range
S – Split
2/3 – 2nd/3rd gear in neutral
R – Reverse gear
Figure 2
48. Ensure that the range servo piston is positioned out 25.4 mm (1 in.) to properly mate with the main 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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49.
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.
50.
Caution
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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50.
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.
51. 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 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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52.
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.
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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53. Install the six upper cover mounting bolts. Tighten fasteners to 24 ±4 Nm (18 ±3 ft-lb).
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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54. Install the control housing. Tighten the fasteners to 110 ±10 Nm (81 ±7 ft-lb).
55. Connect the clutch control valve air supply tube to the upper control housing fitting.
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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55.
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56. Install the plunger, spring and plug for the range function. Tighten plug to 55 ±8 Nm (41 ±6 lb-ft).
57. Connect the clutch valve wiring connector to the control housing.
58. After the control housing has been installed, use PTT to perform calibration operation 4000-07-04-01 “Gearbox
(Gearbox removed)”.
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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58.IMPACT 4.07.82
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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.
59. 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.
60. Carefully install the transmission and align to the engine. Loosely install two upper and two lower transmission-toengine 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.
61. Install the remaining transmission-to-engine mounting bolts. Tighten 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.
62. Position the battery cables and install their mounting bolts.
63. Position the electrical harness and reconnect the control housing, speed sensor and two chassis connectors.
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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63.
64. Install new tie straps to secure the wiring harness to the transmission.
65. Connect the air supply hose at the rear of the transmission.
66. Connect the transmission oil cooler hoses to the filter 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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67. 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)
68. Remove the supporting jack stands and lower the vehicle.
69. Pressurize the air system and check for leaks.
70. Connect all previously removed cables to the negative (ground) battery terminals. Tighten fasteners to 20 ±2 Nm (15
±1.5 ft-lb).
71. Replace the transmission oil filter.
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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71.
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72. Fill the transmission with approved transmission oil.
73. Use PTT to check the transmission electronic control unit (TECU) software, current main software is 23084204. 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.
74. Use PTT to perform calibration operation 4320-07-03-01 “Gearbox, clutch, engagement point”.
75. Clear all diagnostic trouble codes (DTC) prior to returning to service.
Reimbursement
This repair may be Reimbursement Reimbursement
eligible for
UCHP
eWarranty
reimbursement if a
product failure was
experienced within
time and mileage
limits of the
applicable Warranty
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.
37 / 38
IMPACT 4.07.82
coverage.
Reimbursement is
obtained via the
normal claim
handling process.
Claim Type (used
01
only when
uploading from the
Dealer Bus. Sys.)
Labor Code
Primary Labor Code 4319-16-09-01
7.7 hrs.
Causal Part
21480996
11/12/2020
01
3231N-43-80
7.7 hrs.
21480996
MACK Trucks 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.
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.
38 / 38
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TSB/Document ID: KC-183
Replacement Service Bulletin Number:
MFR Communication Date: 2020-11-12
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT
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