NHTSA ID Number: 10183343
Manufacturer Communication Number: KC-387
TSB/Document Date: 2020-12-01
Summary
Vehicles With An Automated Manual Transmission (AMT) - Power Take-Off Diagnosis And Repair; PTO Air Leaks, Oil Leaks, Engagement, Noise
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Vehicles With An Automated Manual
Transmission (AMT) - Power Take-O Diagnosis
And Repair; PTO Air Leaks, Oil Leaks,
Engagement, Noise
:
Internal Content
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The service instructions for the gearbox mounted AMT PTO have not been readily
available to the NA market when the PTO was made available for the AMT in NA.
Although many of the parts have been available for the PTO in the NA parts system, not
all parts are available because major components like gears and housing can quickly
drive the cost of repair higher than the replacement cost. The parts that are available in
NA parts system represent a reasonable repair option when internal inspection of the
PTO and the failure mode show that a simple repair in the eld is possible. See the
failure mode and repair option information below for more information.
Where to nd repair instructions
IMPORTANT
Language settings must be returned to English (United States) after
following the instructions below. CBR will not function correctly if the
language is improperly set in Impact.
Note: Not all dealers or users are set up to be able to do this.
Service instructions are available in Europe for all of the PTOs currently available
in NA. Changes are ongoing to make this information available in the NA market.
Until that happens please use the steps below to nd the service instructions
needed.
1. When looking for information in IMPACT click on the ‘Menu’ tab and select ‘My
Settings’.
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2. Change your preferred language to English (Great Britain) and hit ‘Save’
3. Under the service tab search for Model ‘FH (4)’ -- Select Function Group 48.
Power Take-O -All service information and hit search.
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3.1. Here you will nd Design and Function and service documentation.
4. Select the PTO model you have from the list and then you can download or
print the document for reference.
Note: The PTO model is stamped in the case of the PTO.
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Note: DO NOT forget to change language settings back when nished!
Fail modes
Note: This list assumes the PTO was previously working as designed and has stopped
working properly and is not limited to these descriptions.
Air leaking from gearbox vents when the PTO is engaged.
Air leaking from the vents with PTO engaged is an air seal issue. The seals are available,
as are the gaskets for the repair. The limiting factor is if the bore in the case that the
piston is riding in is scored or worn.
1. Inspect the air piston for wear. Look for evidence of the piston making contact
with the bore as shown in the picture below.
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- If wear is found, the bore needs to be inspected.
2. Inspect the piston bore. Check for any wear or damage as shown in the example
below.
- If the bore is serviceable, the unit should be repaired. Replace the air piston and
seals.
- If the bore is worn, replace the PTO. The piston bore is not repairable.
3. Check the piston and bore for rust.
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- If Rust if found on the piston face, then there has been water intrusion to the
piston. An example is shown below.
○ Check the vehicle air system for moisture and correct the root cause of the water
intrusion.
- If rust damage is found in the bottom of the piston bore, clean the bore and
inspect the sealing surface for damage. Rust in the bottom of the bore will not a ect
operation.
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- If the vehicle air system is dry and properly serviced, the solenoid should be
checked for a good rubber cap on the top.
○ If the cap seal is damaged then replace the solenoid and ttings.
PTO solenoid electrical checks
The PTO solenoid contains two y-back/clamping diodes to prevent high voltage
reverse voltage spikes from damaging the controlling ECU. Because of the orientation
of these diodes, the unit will give unexpected readings for resistance with a multimeter.
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When checking Resistance readings through the solenoid the following readings
with a multimeter should be observed:
- Resistance in the Mega OHM range when measured through normal polarity:
○ Positive lead to Pin 1, Negative lead to Pin 4.
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- Open Circuit (OL) when measuring Resistance through reverse polarity:
○ Negative lead to Pin 1, Positive lead to Pin 4.
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- Diode Check function: Test voltage value when measured with normal polarity:
○ Positive lead to Pin 1, Negative lead to Pin 4.
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- Diode Check function: OL when measured with reverse polarity:
○ Negative lead to Pin 1, Positive lead to Pin 4.
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- Power (12 V) and ground may be applied to the pins in normal polarity (12 V to
Pin 1, Ground to Pin 4) to check the solenoid function.
Applying power in reverse polarity will
damage the solenoid.
• Oil Leaks
All seals and gaskets are available in the parts system. Repair as needed.
- Leaking output ange seals or loose output anges can be repaired on the truck
without removing the PTO from the gearbox if the unit does not need to be
disassembled.
- Oil leaking from top of PTO solenoid will usually include air leaking from the
gearbox vents when the PTO is engaged. The air leaks section above should be
reviewed.
○ NOTE: The customer may not notice the air leak if the PTO is working properly
unless the leak is large or they see an oil mist or ‘smoke’ coming from the vents.
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• PTO Will Not Engage or Disengage, or Grinds During or After Engagement
If the PTO was functioning properly prior to the customer reporting this
symptom, check to see that the PTO ‘tries’ to engage when the switch is turned on.
1. With the switch turned on manipulate the wiring. See if the PTO engages or
disengages due to an electrical issue at the solenoids.
- AMT-C and AMT-D (2007-2016) PTO solenoids are controlled by wiring from the
Transmission Electronic Control Unit (TECU) and will log electrical faults when the
wiring to the solenoids is compromised.
- AMT-F (2017-Present) PTO solenoids are controlled by wiring from the Vehicle
Electronic Control Unit (VECU) and/or the Body Builder Module (BBM) and will not log
electrical faults when the wiring to the solenoids is compromised.
2. If the wiring is veri ed to be intact, the next likely item is a broken snap ring.
- The PTO drive shaft in the rear of the gearbox has a snap ring that contains the
bearing to the shaft. If this snap ring breaks the pieces may end up in the PTO and get
lodged under the shift fork and bind the fork.
- Depending on where the piece gets stuck will depend on how the failure is described.
A snap ring failure may cause a complaint of the gearbox not shifting properly if it
causes the PTO to be stuck in the engaged position. There may also be fault codes
logged like P107371 1st/Rev actuator stuck or P107471 2/3 actuator stuck.
- If it is con rmed that the snap ring is the cause:
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○ Repair as needed.
○ Disassemble and inspect the PTO for repair or replacement.
Examples of snap ring failure can be found below:
Pieces of ring get into the PTO and cause operational issues.
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Spline and sliding clutch: Damaged components should be replaced
PTO case damage from snap ring or other debris can be cleaned up
and inspected. If the damage does not a ect the operation of the
PTO shifter and piston seals the PTO can be repaired.
• Gearbox Low Lube, Mechanical or Contamination Failures
A gearbox that fails for a low lube condition does not necessarily mean that the PTO is
failed also. Contaminated oil may pass through the PTO, but may not necessarily cause
damage. In several cases, PTOs replaced with a gearbox failure that have been
inspected have been deemed acceptable for reuse. The PTO does not spin when not in
use and so does not necessarily damage the internal parts due to low lube or
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contamination seen in the oil. The smaller single PTOs get lube all the time but the
larger double PTOs do not. They only get oil from the gearbox when they are being
used.
In cases of a gearbox failure of this nature, the PTO should be opened and
inspected, cleaned, resealed and reused if the PTO is not failed.
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Except for the dark oil in the housing, this PTO was perfect even though the gearbox
failed for low lube.
Acceptable repairs and available parts
For all the fail modes listed above the repairs are typically straight-forward.
• Seals and gaskets for all PTOs are available in the parts system.
• The available parts include but may not be limited to common fasteners (nuts, bolts,
washers and brackets), seals, gaskets, output anges, sliding clutches and shift forks.
• Check parts availability for the repair.
• When the repair starts to involve the replacement of the PTO case, gears or
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bearings the cost of parts and labor required to repair quickly exceeds the cost of
replacement.
Standard Repair Times
Operation
4811-03-02-02
4811-04-04-01
4814-19-03-01
Description
PTO Replacement (Transmission), All Models
PTR-D
PTR-DH
PTR-DM
PTR-F
Power Take-O , Overhaul. Removed
PTR-FH
PTR-FL
(Refer to appropriate PTO model to the right)
PTRD-D
PTRD-D1
PTRD-D2
PTRD-F
Power Take-o Shaft, Remove-Install, All Models
SRT
0.8 hr
0.4 hr
1.8 hr
1.8 hr
0.8 hr
1.6 hr
1.8 hr
1.4 hr
1.4 hr
1.4 hr
1.4 hr
0.4 hr
VISIBILITY: Dealer distribution
a
Tags
K25756018
P107471
P107371
P1073-71
PTO STAYS ENGAGED
GEARBOX WILL NOT SHIFT PAST 4TH
GRINDING
P1074-71
PTO
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Feedback
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IMPACT 4.07.82
11/30/2020
48171-4 Power Take-off, Overhaul
Removed
Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.
All threaded fasteners that do not have a tightening torque specification in the information are
tightened to a standard torque. Standard torques are available in the following specification.➠
Standard Tightening Torques
CAUTION
Service Information Advisory.
If you are not properly trained and certified in this procedure, ask your supervisor for training before
you perform it.
▶
You must read and understand the precautions and guidelines in Service Information, Function
Group 4, "General Safety Practices, Transmission" before performing this procedure.
Special tools
9992025
9992219
9992267
9992677
9992890
9994034
1
Position the PTO (Power Take-Off) in the vice.
Note
Use soft jaws in the vice.
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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IMPACT 4.07.82
2
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Remove the nut and the washer.
Required material
A
3
COUNTERHOLD
- 6X better wear protection on critical engine parts than...
- 1.3X better sludge protection than industry standards*
- 3X Stronger against viscosity breakdown than leading full...
- Protection for 10,000 miles between oil changes
- Meets or exceeds the following specifications: API SP/SN...
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TSB/Document ID: KC-387
Replacement Service Bulletin Number:
MFR Communication Date: 2020-11-18
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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