NHTSA ID Number: 10219299
Manufacturer Communication Number: KC-219
TSB/Document Date: 2022-09-07
Summary
oil in the control housing of the transmission diagnostics
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TSB/Document ID: KC-219
Replacement Service Bulletin Number:
MFR Communication Date: 2022-08-29
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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8/30/22, 11:19 AM
Article
Oil In Control Housing Or TECU -- AMT-F
Internal Content
IMPORTANT
If there is oil leakage from the gearbox vents or a report of 'smoke' or
'oil mist' during shifting, gear box testing or PTO operations
accompanied with excessive air leakage during these operations:
Article CBR-343 for Mack
and CBR-338 for Volvo should be
referenced.
If there is no air leakage or only slight air leakage from vents
during countershaft brake testing and oil is found in the control
housing:
1. Remove the gearbox from the vehicle.
2. Remove the countershaft brake air line.
3. Check for the presence of oil in the air line or check the exhaust port
on the solenoid block for the presensce of oil.
If oil is found in the countershaft brake airline or the solenoid block
then repair or replace the countershaft brake as needed. Oil in the
solenoid block does not affect the operation and can be cleaned and
reused following the instructions below.
The clutches in the countershaft brake must also be replaced.
The Countershaft brake assembly is not available as an assembly.
Order parts as needed. Repair instructions are availiable in IMPACT
for the countershaft brake piston assembly.
Clean the oil from the inside of the control housing and from the
TECU with a clean cloth and blow it dry with compressed air. Cleaning
sprays like brake cleaner are not recommended by WABCO for
cleaning the electrical components like the solenoids harnesses and
circuit boards. Unplug the connectors from the circuit board and
clean the oil from inside the connections with compressed air and
wipeUIoff any residue. Clean all the air passages for the countershaft
; Live
brake and reassemble the unit.
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NOTE: Bench test assembly before reinstallation.
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Article
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5/5
8/31/22, 12:57 PM
Article
Mack Chassis - mDRIVE Transmission - AMT Gear
Box Air Leaks
Internal Content
Complaint:
Air leak from the left or right side vent of the TECU all the time. AMT-D:
See Figures 2 and 3.
Air leak from gearbox case vent tube all the time AMT-C: see Figure 5
Cause:
AMT - C & D; One or more TECU shift valves have become stuck open
allowing the air path to the open venting solenoid. This can be an
intermittent issue. Testing and investigation has shown that exercising
the valves with TT by forcing shifts can ‘unstick’ the valves and the leak
might not return however there is a good chance that the valve will
become stuck again. TECU to control housing seals can leak causing
symptoms like described and should be checked prior to major
component replacement. A leak between ports in the TECU due to a
failed gasket like in picture below can cause erratic or undesired
shifting due to air bleeding to the wrong ports during shifting. The
seals should be pliable and have a peaked appearance. This seal is
bad due to the flattened sealing surfaces.
1/8
8/31/22, 12:57 PM
Article
2/8
8/31/22, 12:57 PM
Article
Repair:
Replace TECU to Control housing seals if faulty and retest
Replace TECU
Complaint:
Air leak only when shifting or certain gears are not avail during
operation or slow shifting accompanied by an air leak.
Cause:
Air leaks like these are in the shift control housing and not the TECU.
Causes of these leaks are typically screws backed out of the shift
piston covers (see figure 4) that allow the end cap to come out and
vent air to the case during a shift. This will typically only be affecting
one shifter and only when the shifter is asked to move in only one
direction. The complaint may indicate that several gears are
UI
; Live
unavailable at random times. The TECU will find these gears and will
https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40basec…
3/8
8/31/22, 12:57 PM
Article
try and avoid them if possible during operation. This may not always
happen consistently but in an effort allow unit operation the TECU will
abandon certain gears. A key cycle will typically reset this learning and
the unit will have to relearn the ‘bad’ gears.
Other causes of these types of leaks are broken shift forks piston rods
and cracked internal pistons. The broken rods can be identified by
inspection after removal of the control shift housing and manipulation
of the shift forks. One of them will feel like it is ‘not attached to
anything inside’. An AMT-C with external vent tubes on the right side
of the gearbox will vent air from the vent tubes when these two
failures occur. An AMT-D is internally vented through the TECU and
will leak air from the vents on the TECU.
Warning: Do not transfer the external vent tubes from an AMT-C to
an AMT-D gearbox during a repair.
The other types of failure that can occur and cause leaks during
shifting are broken/cracked internal shift pistons. This failure will in
addition to having an air leak will be a slow shift of the failed piston.
These failures will vent through the TECU vents on all AMT versions.
Cracked pistons will vent air from the TECU vents but this is only
during shifting. Air leaks during shifting can also be caused by a
leaking countershaft brake assembly, CVU or CCA. Testing of these
components is needed prior to replacing the control housing
assembly.
Repair:
Replace shift control housing only, unless other damage is found.
Complaint:
Gearbox slow to engage a gear from Neutral or shift quality is bad.
Slow to shift between gears or harsh shifting. Air leak heard from
clutch/flywheel housing.
UI
; Live
Cause:
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8/31/22, 12:57 PM
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Air leak on CCA (Clutch control Actuator) inside clutch housing.
Air leak on Countershaft brake assembly
Perform clutch release tests in TT and listen for excessive air to escape
during these tests. Some air venting is normal but long blasts of air
are not normal.
Repair:
Inspect and replace the cause of the leak. Tech tool can be used to
manipulate the clutch actuator with the gearbox in or out of chassis to
investigate this type of leak. Use 4111-08-04-01 - PWM Valves Clutch
Activation, Test (Transmission Removed) or 4111-08-03-06 - PWM
Valves Clutch Activation, Test to pressurize the clutch system to check
for leaks.
Internal AMT-D venting
The internal venting of the AMT-D is provided in the bearing
retainer plate for the rear main shaft bearing. This provides
venting and oil separation for return back to the gearbox.
5/8
8/31/22, 12:57 PM
Article
AMT-D gearbox venting with bearing retainer removed. All of this
is contained behind the high range synchronizer cone in the rear
of the gearbox.
The Vent port is cast and drilled in the main case and leads into
the control housing and TECU and is vented through the ports on
the left side of the main case.
6/8
8/31/22, 12:57 PM
Article
Internal ports in the control housing and the air path for gearbox
case venting.
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7/8
8/31/22, 12:57 PM
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8/8
8/31/22, 12:58 PM
Article
Volvo Chassis - I-Shift Transmission - AMT Gear
Box Air Leaks
Internal Content
Complaint:
Air leak from the left or right side vent of the TECU all the time. AMTD: See Figures 2 and 3.
Air leak from gearbox case vent tube all the time AMT-C: see Figure 5
Cause:
AMT - C & D; One or more TECU shift valves have become stuck open
allowing the air path to the open venting solenoid. This can be an
intermittent issue. Testing and investigation has shown that
exercising the valves with TT by forcing shifts can ‘unstick’ the valves
and the leak might not return however there is a good chance that
the valve will become stuck again. TECU to control housing seals can
leak causing symptoms like described and should be checked prior to
major component replacement. A leak between ports in the TECU due
to a failed gasket like in picture below can cause erratic or undesired
shifting due to air bleeding to the wrong ports during shifting. The
seals should be pliable and have a peaked appearance. This seal is
bad due to the flattened sealing surfaces.
1/9
8/31/22, 12:58 PM
Article
2/9
8/31/22, 12:58 PM
Article
Repair:
Replace TECU to Control housing seals if faulty and retest
Replace TECU
UI
Complaint:
; Live
https://volvo-trkna-prod1.pegacloud.net/prweb/PRAuth/app/VolvoKM_/iNPUIKpeinqPJi2G0hH930k43USdE1gb*/!TABTHREAD1?pyActivity=%40basec…
3/9
8/31/22, 12:58 PM
Article
Air leak only when shifting or certain gears are not avail during
operation or slow shifting accompanied by an air leak.
Cause:
Air leaks like these are in the shift control housing and not the TECU.
Causes of these leaks are typically screws backed out of the shift
piston covers (see figure 4) that allow the end cap to come out and
vent air to the case during a shift. This will typically only be affecting
one shifter and only when the shifter is asked to move in only one
direction. The complaint may indicate that several gears are
unavailable at random times. The TECU will find these gears and will
try and avoid them if possible during operation. This may not always
happen consistently but in an effort allow unit operation the TECU will
abandon certain gears. A key cycle will typically reset this learning and
the unit will have to relearn the ‘bad’ gears.
Other causes of these types of leaks are broken shift forks piston
rods and cracked internal pistons. The broken rods can be identified
by inspection after removal of the control shift housing and
manipulation of the shift forks. One of them will feel like it is ‘not
attached to anything inside’. An AMT-C with external vent tubes on
the right side of the gearbox will vent air from the vent tubes when
these two failures occur. An AMT-D is internally vented through the
TECU and will leak air from the vents on the TECU.
Warning: Do not transfer the external vent tubes from an AMT-C to
an AMT-D gearbox during a repair.
The other types of failure that can occur and cause leaks during
shifting are broken/cracked internal shift pistons. This failure will in
addition to having an air leak will be a slow shift of the failed piston.
These failures will vent through the TECU vents on all AMT versions.
Cracked pistons will vent air from the TECU vents but this is only
during shifting. Air leaks during shifting can also be caused by a
leaking countershaft brake assembly, CVU or CCA. Testing of these
components is needed prior to replacing the control housing
assembly.
4/9
8/31/22, 12:58 PM
Article
Repair:
Replace shift control housing only, unless other damage is found.
Complaint:
Gearbox slow to engage a gear from Neutral or shift quality is bad.
Slow to shift between gears or harsh shifting. Air leak heard from
clutch/flywheel housing.
Cause:
Air leak on CCA (Clutch control Actuator) inside clutch housing.
Air leak on Countershaft brake assembly
Perform clutch release tests in TT and listen for excessive air to
escape during these tests. Some air venting is normal but long blasts
of air are not normal.
Repair:
Inspect and replace the cause of the leak. Tech tool can be used to
manipulate the clutch actuator with the gearbox in or out of chassis
to investigate this type of leak. Use 4111-08-04-01 - PWM Valves
Clutch Activation, Test (Transmission Removed) or 4111-08-03-06 UI
; Live
PWM Valves Clutch Activation, Test to pressurize the clutch system to
check for leaks
5/9
8/31/22, 12:58 PM
check for leaks.
Article
Internal AMT-D venting
The internal venting of the AMT-D is provided in the bearing
retainer plate for the rear main shaft bearing. This provides
venting and oil separation for return back to the gearbox.
AMT-D gearbox venting with bearing retainer removed. All of this
is contained behind the high range synchronizer cone in the rear
of the gearbox.
6/9
8/31/22, 12:58 PM
Article
The Vent port is cast and drilled in the main case and leads into
the control housing and TECU and is vented through the ports on
the left side of the main case.
; Live UI
Internal ports in the control housing and the air path for gearbox
7/9
8/31/22, 12:58 PM
Article
Internal ports in the control housing and the air path for gearbox
case venting.
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vnm
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