IMPACT 3.

0 Wednesday, 14 May 2014

Chassis ID Path
43/Repair/FM, ATO2812C/Gearbox, disassemble-inspect-assemble. Gearbox removed

Model Identity
FM 132790696

Publish date ID/Operation No.

Saturday, 8 March 2014 43187-4

43187-4 Gearbox, disassemble-inspect-assemble

Gearbox removed

Illustrations are used for several different variants: some details may therefore differ from the variant you are working
on. The essential information in the illustrations is however always correct.

Note: For replacement of GCU (Gear Control unit) or TECU, read first - MID 130 PID 160 Parameter setting .

Warning
Always wear safety glasses when using compressed air in the gearbox.

Special tools: 9986485, 9989876, 9990027, 9990028, 9990029, (2x) 9990031, 9990120, , 9992000, 9992215,
9992337, 9992613, 9992619 , 9992671, 9996041, 9996042, 9996081, 9996176, 9996222, 9996239, 9996315,
9996479, 9996483, 9996876, 9996889, 9996901, 9996905, 9996910, 9996917, 9996925, 9998051, 9998401,
9998542, 9999696, 9999737, 88800211, 88800006, 88800015, 88800033, 88800034, 88800035, 9992003

Other special equipment: 88890148, 88890149

Contents

Disassembly.
Inspection.
Assembly.

Disassembly
Important information before disassembling the gearbox.

Important information before disassembling the gearbox, check the condition of the clutch housing and basic
housing.

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IMPACT 3.0 Wednesday, 14 May 2014

The following checks must be carried out during the procedure:

1. Check if there is any axial play in the main shaft and countershaft. It must be less than 0.25 mm.
If the axial play is greater than 0.25 mm, replace the clutch housing and bearings with new parts with
locking pins. See step 59.
2. Check the bearing's outer races for the input shaft and countershaft in the clutch housing. They must be
held still and not be able to rotate at room temperature.
If the bearing rotates: apply Loctite 638 (P/N 1161370). See step 80.
3. Check the distance between the basic housing and the bearing's outer race on the main shaft and the
countershaft. Use a feeler gauge 0.05 mm thick and with a maximum width of 10 mm. It must not be
possible to insert the feeler gauge.
1. If the feeler gauge can be inserted, replace the basic housing, caps and bearings.
2. If the feeler gauge cannot be inserted: check rotation of the bearing outer race.
If the outer bearing race rotates: replace the two caps and bearings for ones with locking pins. In
this case, do not replace the base housing and clutch housing.
See step 66.

The following actions must be carried out based on the results of the above checks:

If criteria 1 is not met, the gearbox must be updated to the variant with locking pin for the outer bearing
races, on both the clutch housing and the base housing. See step 90–91and97–98.
If criteria 2 is not met, apply Loctite 638 (p/n 1161370).
If in criteria 3 it is not possible to insert a 0.05 mm, 10 mm long feeler blade, but the bearing is rotating,
the rear bearings for the main shaft and counter-shaft and the rear caps must be replaced with new
bearings and caps with locking pins. In this case, do not replace the basic housing.
If in criteria 3 it is possible to insert the 0.05 mm feeler gauge blade, replace the basic housing, plus the
rear bearings for the main shaft and counter-shaft and the rear caps for the beakers and caps with
locking pin.

Note: if the gearbox already had bearings and rear caps with locking pins, these parts will be replaced
only when they are faulty.

On older gearboxes with long mileages, the existing parts can be reconditioned and the bearing's outer races
glued in the clutch housing. Use VOLVO glue P/N 1161370.

Note! The bearing's outer races in the basic housing must not be glued due to the adjustment of the bearing
pretensioning.

The above upgrading to a variant with locking pins for the bearing's outer races requires a number of parts to
be replaced at the same time.

Clutch housing with locking pins

Complete front bearing, both for the main shaft and countershaft, with recess for the locking pin in the
outer bearing race.
Complete rear bearing, both for the main shaft and countershaft, with recess for the locking pin in the
outer bearing race.
Cover for main shaft with locking pin.
There are two different covers depending on version of gearbox ventilation. For more information read
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IMPACT 3.0 Wednesday, 14 May 2014

chapter ventilation in Gear box, manual .

Cover for countershaft with locking pin
Screws for cover, both for the main shaft and countershaft
Shims for adjusting the pretension for both the main shaft and countershaft

1
Clean the outside of the gearbox.

Note: Plug nipples and valves during high pressure washing.

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IMPACT 3.0 Wednesday, 14 May 2014

Connect a computer with the VCADS program installed. Use 40091-3 Gearbox activation, control housing (for
removal/fitting). In order for you to be able to remove the control housing, the splitter gear must be in its rear position,
2nd and 3rd in neutral and 1st/reverse in the rear position and set to the high range.
Go to step14if the VCADS program makes contact with TECU. Otherwise go to the next step.

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IMPACT 3.0 Wednesday, 14 May 2014

Note: If VCADS Pro cannot make contact with the TECU the control housing must be manually moved to the correct
position so that it can be lifted away from the gearbox.

The illustration shows the positions that the different air cylinders in the control housing must have in order for the
control housing to be lifted away.
In order for you to be able to remove the control housing, the splitter gear must be in its rear position, 2nd and 3rd in
neutral and 1st/reverse in the rear position and set to the high range.

Remove the screws holding the control housing on the gearbox. Remove the screws holding the cover on the TECU.
The figure shows the screw for the cover.

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IMPACT 3.0 Wednesday, 14 May 2014

Carefully lift the cover and disconnect the cable harness between the cover and control housing.

Fit 4 screws (see figure). Tighten the screws so as not to damage the surface of the control housing. This ensures that
the control housing cannot move and damage the pulse wheel on the main shaft.

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IMPACT 3.0 Wednesday, 14 May 2014

DD

OD
The figure shows where the various air ducts are that are used to manually operate the control housing air cylinders.
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IMPACT 3.0 Wednesday, 14 May 2014

DD

OD
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IMPACT 3.0 Wednesday, 14 May 2014

Put the splitter gear in its rear position using a compressed air nozzle. If possible engage the forward position first in
order to check that the splitter gear moves correctly.

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IMPACT 3.0 Wednesday, 14 May 2014

Put the range gear in its forward position using a compressed air nozzle. If possible engage the rear position first in
order to check that the splitter gear moves correctly.

10

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IMPACT 3.0 Wednesday, 14 May 2014

Check whether the gearbox is in neutral by turning the output shaft companion flange. If it does, blow in the hole for
reverse to engage the basic gearbox reverse gear. If not, go to the next step.

11

If it is not possible to engage reverse gear, engage 2nd or 3rd gear.

The 2nd and 3rd gear air cylinder must be in neutral before reverse gear can be engaged. Note that there is a
mechanical engagement interlock built into the control housing that makes it impossible to engage reverse unless 2nd
or 3rd gear air cylinder is in neutral.

12

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IMPACT 3.0 Wednesday, 14 May 2014

Use a compressed air nozzle to put 2nd and 3rd gear air cylinders in neutral by carefully blowing into 2nd and 3rd gear
holes while at the same time turning the output shaft companion flange a little in order to better feel when neutral is
engaged.

13
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IMPACT 3.0 Wednesday, 14 May 2014

Use a compressed air nozzle to engage the basic gearbox reverse gear.

14

Remove the electrical connector for the clutch valve assembly in the control housing.

15

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the pneumatic connection to the valve assembly, and remove the three screws securing the valve assembly.

16

Remove the electrical connection for the clutch position sensor on the valve assembly. Remove the valve assembly.

17

Fit the spacer flange onto the fixing plate. With the aid of the arm, fit the fixing plate to the gearbox. Secure the gearbox
into the unit stand.

Note: It will be necessary (2x) 9990031.

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IMPACT 3.0 Wednesday, 14 May 2014

Special tools: 9986485, 9990031, 9996905, 9999737

18

Drain the gearbox oil.

Warning
Hot oil can cause burns. Use protective gloves.

19

Remove the oil filter drain plug. Refit the drain plug after the oil has finished draining.

20

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the oil filter cover and guide sleeve.

Note: There will be some oil left in the cover.

21

Remove the oil filter housing and where applicable the oil cooler.

22

Remove the control housing. If necessary, carefully use a crowbar to loosen the control housing from its guide pins.

Special tools: 9992337

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IMPACT 3.0 Wednesday, 14 May 2014

23

Fit the magnetic stand and dial gauge on the holder. Check the runout in the sensor wheel. The measuring tip of the
dial gauge must be 2 mm below the teeth. The maximum permitted runout is 0.4 mm.

Special tools: 9999696, 9989876, 9990029

24
If the gearbox is equipped with a retarder, perform step25–27. Otherwise go to step28.

25

Remove the retarder's temperature sensor from the heat exchanger or alternatively, remove the connector from the
plate.

26

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the retarder wiring cable ties.

27

Remove the three screws securing the heat exchanger and retarder cooler.

28
Turn the gearbox so that the output shaft flange faces upwards.

29

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IMPACT 3.0 Wednesday, 14 May 2014

Fit counterhold 9998570.

Remove the companion flange nut and O-ring.

Special tools: 9998570

30

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the companion flange.

Special tools: 9990084, 9992619, 9992671, 9996156, 9996222, 9998597

31

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the plug, spring and blocking body for the range function. If necessary use a magnet to pull out the blocking
body.

32
If the gearbox is equipped with a retarder, perform step33–34. Otherwise go to step35.

33

Remove the four nuts securing the retarder to the range housing (A, B, C and D in the illustration).

34
Carefully lift the retarder away from the gearbox.

35

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the range housing securing screws.

Note: If the gearbox has a retarder, do not forget to remove the screws from the retarder socket.

36

Fit the adapter and lifting eye into the output shaft.

Special tools: 9996479, 9996925

37

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IMPACT 3.0 Wednesday, 14 May 2014

Split the main housing and range housing. Use press tool.

Special tools: 9998051

38
Lift the range housing away carefully.

Note: Ensure that the range cylinder piston rod does not jam in the gearbox housing, the shaft may then be damaged.

39

Remove the oil distributor pipe. Use a socket.

Special tools: 9990027

40

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the circlip securing the high range synchronizer.

41

Remove both halves of the washer.

42

Fit both the puller halves on to the high range synchronizer hub.

Special tools: 88800015

43

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IMPACT 3.0 Wednesday, 14 May 2014

Fit one half of the puller 9998542 on to the puller rings, together with the hydraulic cylinder, spindle and drift.

Note: Ensure that the split in the puller rings is at 90° to the split in the puller.

Special tools: 88800015, 9998542, 9992671, 9996889, 9998542

44

Fit the other half of the puller 9998542. Fit the hydraulic pump. Press off the high range synchronizer.

Special tools: 9996222

45

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the reversing shaft centre screw.

46

Remove the countershaft cover and shim.

47

Fit the puller and spindle to the reversing shaft.

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IMPACT 3.0 Wednesday, 14 May 2014

Special tools: 9996315, 9996917

48

Fit the hollow drift, hydraulic cylinder and hydraulic pump to the spindle.

Special tools: 9990120, 9992671, 9996222

49
Press out the reversing shaft.

50

Remove the oil pump with the reverse gear pinion.

51

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the shim and the countershaft cover.

52

Fit screw 9996917 on to the main shaft and screw 9996483 on the counter shaft.

Special tools: 9996917, 9996483

53

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IMPACT 3.0 Wednesday, 14 May 2014

Rotate the shafts 20 turns.

54

Attach the dial gauge to the magnetic stand. The tip of the dial gauge should touch the sun wheel.
Zero the dial gauge and mark up the measurement point.

Special tools: 9989876, 9989876

55
Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off a possible axial play at the
marked position and note it.

56

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IMPACT 3.0 Wednesday, 14 May 2014

Attach the dial gauge to the counter shaft. The tip of the dial gauge should touch the counter shaft. Zero the dial gauge
and mark up the measurement point.

57
Turn the gearbox over 1/2 turn.

58
Lift the tip of the dial gauge and rotate the shafts at least 20 turns. Read off a possible axial play from the marked
measurement point and note the value.

59
Check if there is any axial play in the main shaft and countershaft. It must be less than 0.25 mm.
If the axial play is greater than 0.25 mm, replace the clutch housing and locking pin bearing with new parts.

Specifications:
Permissible end play: 0.25 mm

60
Turn the gearbox over 1/2 turn.

61

Remove
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IMPACT 3.0 Wednesday, 14 May 2014

Dial indicator 9989876

Magnetic stand 9999696
Bolt 9996917
Bolt 9996483

Special tools: 9989876, 9999696, 9996917, 9996483

62

Remove the countershaft cover and shim.

63

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the main shaft cover and the overdrive's oil pipe, where applicable.
Remove the main shaft shim.

Note: Two alternatives, A and B

64

Check the part no. of the spacer sleeve and check TPI 431-033 in the parts information.
If necessary, replace the spacer sleeve before assembly.116

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IMPACT 3.0 Wednesday, 14 May 2014

65

Remove the spacer sleeve.

66

Check the distance between the basic housing and the bearing's outer race on the main shaft and the countershaft.
Use a feeler gauge 0.05 mm thick and with a maximum width of 10 mm. It must not be possible to insert the feeler
gauge.

1. If the feeler gauge can be inserted, replace the basic housing, caps and bearings.
2. If the feeler gauge cannot be inserted: check rotation of the bearing outer race.
If the outer bearing race rotates: replace the two caps and bearings for ones with locking pins. In this case, do
not replace the base housing and clutch housing.
If the outer bearing race does not rotate: continue to step67.

Note: The measurement shall be performed at room temperature. The house should not be heated up to more than 30°
C.

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IMPACT 3.0 Wednesday, 14 May 2014

67
Turn the gearbox so that the input shaft faces upwards.

68

Remove the clip securing the air hose in the clutch cylinder. Carefully remove the clamps for the electrical cable and
the air hose to the clutch cylinder. Remove the three clutch cylinder screws.

69

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the air hose for the clutch cylinder and the air pipe for the counter shaft brake.

70

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the counter shaft brake.

71

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the piston A and spring B for the counter shaft brake.

72
Remove the clutch housing.

73

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the air pipe nipple for the counter shaft brake pipe.

74

Remove the sleeve from the intermediate shaft.

75
Remove the magnet between the clutch housing and the lower part of the basic housing. Clean the magnet.

76

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IMPACT 3.0 Wednesday, 14 May 2014

Prepare the lifting tool as illustrated. Use the two lifting arms and the spacer ring from special tool 9990028, lifting arm
kit 88800006, fixture plate and chain. Fit the lifting tool into the shaft assembly.

Special tools: 88800006, 9990028, 9996239, 9996910

77

Make a wooden fixture as illustrated to receive the shaft package.

Note: The main shaft must not be placed on a workbench or similar. This can damage the gear teeth. Therefore all
work must be carried out with the main shaft upright.

78

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IMPACT 3.0 Wednesday, 14 May 2014

Carefully lift out the shaft assembly and place it in the wooden fixture.

79
Remove the lifting tool from the shaft assembly.

80

Check the bearing's outer races for the input shaft and countershaft in the clutch housing.

Note: They must be held still and not be able to rotate at room temperature.

If the bearing rotates: apply Loctite 638 (p/n 1161370).

If the bearing does not rotate: continue to step81.

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IMPACT 3.0 Wednesday, 14 May 2014

Specifications:
p/n :1161370

81

Pull the countershaft's outer race out of the clutch housing. Use a puller, yoke, cylinder, pump and spindle.

Note: Only remove the outer race if the bearing will be changed.

Special tools: 88800033, 88800035, 9992671, 9996041, 9996222

82

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41 / 80
IMPACT 3.0 Wednesday, 14 May 2014

Pull the input shaft's outer race out of the clutch housing. Use a puller, yoke, cylinder, pump and spindle.

Note: Only remove the outer race if the bearing will be changed.

Special tools: 88800033, 88800034, 9992671, 9996041, 9996222

83

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the seal for the input shaft. Use a lever.

Note: Replace the seal if necessary.

Special tools: 9992337

84

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IMPACT 3.0 Wednesday, 14 May 2014

Drive the outer race of the counter shaft rear bearing out of the gearbox housing. Use a drift and handle.

Note: Only remove the outer race if the bearing will be changed.

A= 9992000
B= 9996081

Special tools: 9992000, 9996081

85

Drive the outer race of the main shaft rear bearing out of the gearbox housing. Use a drift and handle.

Note: Only remove the outer race if the bearing will be changed.

Special tools: 9992613, 9996176

86

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IMPACT 3.0 Wednesday, 14 May 2014

Remove the oil screen and the overflow valve.

Inspection
87
The components must be washed clean and dried.

88
Check bearings, shafts, gears and synchronizers for damage and wear. Replace damaged or worn parts.

Caution
New bearings and bearing races must be taken from the same package.

89
Lubricate all parts with gearbox oil before installation.

Assembly
90

Check if the rear covers have locking pins fitted.

If they are provided with locking pins, note the position of the pins on the housing using a marker pen.

If not provided with locking pins, we recommend to upgrade to the variant with locking pins for the bearing's outer races
in both the clutch housing and the basic housing.
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IMPACT 3.0 Wednesday, 14 May 2014

Alternatively, for older gearboxes with long mileages, the existing parts can be refitted.

91

Align the groove in the outer races with the marked positions of the lock pins. Drive the outer race of the main shaft
rear bearing into the housing until the outer race is about 5 mm above the bottom of the gearbox housing. Do the same
thing for the outer race for the counter shaft.
If the outer races have not been removed, they should be tapped out so that they are about 5 mm above the bottom of
the gearbox housing.

Note: This step must be carried out so that the shaft pretensioning can later be adjusted.

92

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IMPACT 3.0 Wednesday, 14 May 2014

Turn the gearbox over 1/2 turn. Fit the oil screen and overflow valve. Torque tighten the valve.

Other special equipment: 1159794

Specifications:
45 ± 5 Nm

93

Assemble the shaft assembly. Secure the lifting tool to the shaft assembly. Lubricate all bearings.

Note: It is important that the bearings are oiled, to give the correct clearances.

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IMPACT 3.0 Wednesday, 14 May 2014

Special tools: 88800006, 9990028, 9996239, 9996910

94
Carefully lift the shaft assembly into the gearbox housing.

95
Remove the fixture and the three lifting arms from the shafts.

96

Install the nipple for the air pipe for the counter shaft brake.

97

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IMPACT 3.0 Wednesday, 14 May 2014

Check if the clutch housing is fitted with locking pins.

If it is provided with locking pins, note the position of the pins on the housing using a marker pen.

If not provided with locking pins, we recommend to upgrade to the variant with locking pins for the bearing's outer races
in both the clutch housing and the basic housing.

Alternatively, for older gearboxes with long mileages, the existing parts can be refitted and the bearing outer races
glued in the clutch housing. Use VOLVO glue with part no. 1161370. This alternative is not as reliable as upgrading to
locking pins.

Note: Don't use excessive amount of glue, use only the necessary.

Note: The bearing's outer races in the basic housing must not be glued due to the adjustment of the bearing
pretensioning.

When replacing the clutch housing, where you have chosen not to make the recommended upgrade to the variant with
locking pins for the bearing outer races (see Important information before disassembling the gearbox.), the locking pins
can be removed and the new clutch housing be used also for earlier version.

98

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IMPACT 3.0 Wednesday, 14 May 2014

Align the groove in the outer races with the marked positions of the lock pins.

99

Drive the countershaft's outer race into the clutch housing until it reaches the end position.

Special tools: 9992003, 9996041, 9996042, 9992671, 9996222

100
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IMPACT 3.0 Wednesday, 14 May 2014

Drive the input shaft's outer race into the clutch housing until it reaches the end position.

Special tools: 9992671, 9996041, 9996042, 9996081, 9996022, 9998401

101

Apply VOLVO-recommended sealing fluid for high temperatures to the main housing's contact surfaces on the clutch
housing as shown in the figure. Fit the magnet.

102
Place the clutch housing on the basic housing. Check that the guide pins locate in the holes in the clutch housing.
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IMPACT 3.0 Wednesday, 14 May 2014

103
Fit the clutch housing screws and torque tighten them alternately.

Other special equipment: 1159795

Specifications:
110 ± 10 Nm

104

Press in a new seal for the input shaft with a drift, (A) 88800211.

Note: Fill the space between the seal lips to 1/3 with a VOLVO approved grease. Avoid getting grease on the felt ring.
Oil in the sealing ring mating face to the input shaft before assembly.

Special tools: 88800005

105
Turn the gearbox over 1/2 turn.

106

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IMPACT 3.0 Wednesday, 14 May 2014

Install a shim with thickness approximately 0.9 mm.

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

When replacing the cover, where you have chosen not to do the recommended upgrade to the variant with locking pins
for the bearing outer races (see Important information before disassembling the gearbox.), do as follows:

For older variants without locking pins, the locking pins can be removed and the new cover with new screws can
be used.
For variants that have an O-ring fitted by the bearing, the O-ring must be discarded, the locking pin removed and
the new cover with new screws be used.

107

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the main shaft's cover with the shim.

Note: Torque tighten the screws diagonally, use new screws.

Note: There are two different covers (A and B) depending on version of gearbox ventilation. For more information read
chapter ventilation in Gearbox, mechanical .

Specifications:
40±5 Nm

108

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IMPACT 3.0 Wednesday, 14 May 2014

Install a shim with thickness approximately 0.9 mm.

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

When replacing the cover, where you have chosen not to do the recommended upgrade to the variant with locking pins
for the bearing outer races (see Important information before disassembling the gearbox.), do as follows:

For older variants without locking pins, the locking pins can be removed and the new cover with new screws can
be used.
For variants that have an O-ring fitted by the bearing, the O-ring must be discarded, the locking pin removed and
the new cover with new screws be used.

109

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the countershaft's cover with the shim.

Torque tighten the screws diagonally.

Note: When replacing the cover, use new screws.

Specifications:
40±5 Nm

110

Lock the gears with the holder for the clutch sleeves.

Note: When measuring the main and counter shaft, gear 2 LS shall be engaged.
Without overdrive: The splitter gear clutch ring in its frontmost position.
With overdrive: The splitter gear clutch ring in its rearmost position.
The counter shaft brake must not be engaged.

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IMPACT 3.0 Wednesday, 14 May 2014

Special tools: 9990029

111

Fit screw 9996917 on the main shaft and screw 9996483 on the counter shaft.

Special tools: 9996917, 9996483

112

Rotate the shafts 20 turns.

113

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IMPACT 3.0 Wednesday, 14 May 2014

Attach the dial gauge to the magnetic stand. The tip of the dial gauge should touch the sun wheel. Zero the dial gauge
and mark up the measurement point.

Special tools: 9989876, 9999696

114
Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off the axial play at the marked
position and note it.

115

Turn the gearbox 1/2 turn.

Remove the main shaft cover.

Note: Two alternatives, A and B

Note: If the main shaft has been recently overhauled skip steps 114 and 115, and go to step 116.
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IMPACT 3.0 Wednesday, 14 May 2014

116

When replacing the spacer sleeve, reuse the piston rings with the new spacer sleeve.

117

Fit the spacer sleeve.

Special tools: 9996222, 9992671, 88800246, 9996315, 9996917

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IMPACT 3.0 Wednesday, 14 May 2014

118

Fit a shim that is 0.1 to 0.2 mm thicker than the measured clearance together with the shim to be used. This gives a
pretensioning of between 0.1 and 0.2 mm.

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

119

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the main shaft's cover with the shim.

Note: Torque tighten the screws diagonally, use new screws.

Note: There are two different covers (A and B) depending on version of gearbox ventilation. For more information read
chapter ventilation in Gearbox, mechanical .

Specifications:
40±5 Nm

120

Rotate the shafts 20 turns.

121

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IMPACT 3.0 Wednesday, 14 May 2014

Attach the dial gauge to the counter shaft. The tip of the dial gauge should touch the counter shaft. Zero the dial gauge
and mark up the measurement point.

122
Turn the gearbox over 1/2 turn.

123
Lift the tip of the dial gauge and rotate the shafts at least 20 turns. Read off the axial play from the marked
measurement point and note the value.

124
Turn the gearbox over 1/2 turn.

125

Remove

Dial indicator 9989876

Magnetic stand 9999696
Bolt 9996917
Bolt 9996483

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IMPACT 3.0 Wednesday, 14 May 2014

Special tools: 9989876, 9999696, 9996917, 9996483

126

Remove the countershaft's cover.

127

Fit a shim that is 0.1 to 0.2 mm thicker than the measured clearance together with the shim to be used. This gives a
pretensioning of between 0.1 and 0.2 mm.

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
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IMPACT 3.0 Wednesday, 14 May 2014

in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

128

Fit a new gasket on the oil pump.

129

Install the oil pump. Knock the reversing shaft into the gearbox housing using a plastic mallet. Fit the screws into the
reversing gear and torque tighten.

Note: Make sure that the bevel for the rotation lock is in the correct position.

Other special equipment: 1159794

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IMPACT 3.0 Wednesday, 14 May 2014

Specifications:
48±8 Nm

130

Fit the countershaft's cover with the shim.

Note: Torque tighten the screws diagonally.

Other special equipment: 1159794

Specifications:
40±5 Nm

131
Where applicable fit the overdrive oil pipe.

132

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IMPACT 3.0 Wednesday, 14 May 2014

Press in the synchronizer for high range.

Note: It will be necessary to fit tool 9996917 as in step 117.

Special tools: 9990015, 9992671, 9996081, 9996022, 9996315, 9998542, 9996917

133

Fit both the washer halves.

134

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the high range circlip.

Note: The circlip is available in seven thicknesses. Choose the thickest circlip that assures a residual play of maximum
0.05 mm.

135

Remove the forks 9990029 holding the clutch sleeves in place.

Special tools: 9990029

136

Oil and fit new O-rings. Install the oil distribution piping. Torque tighten the oil distribution piping. Use a socket.
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IMPACT 3.0 Wednesday, 14 May 2014

Special tools: 9990027

Other special equipment: 1159795

Specifications:
250 ± 35 Nm

137

Apply VOLVO approved high-temperature liquid gasket.

138

Fit the adapter and lifting eye into the range section output shaft. Position the range housing over the main housing.
Lower and line up the piston rod and planet wheel. Secure the range housing. Torque tighten the bolts.

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IMPACT 3.0 Wednesday, 14 May 2014

Note: Insert the guide pins 9996876 into the gearbox housing to facilitate the assembly.

Special tools: 9996479, 9996876, 9996925

Other special equipment: 88890149

Specifications:
110 ± 10Nm

139

Fit the adapter and lifting eye into the range section output shaft. Position the range housing over the main housing.
Lower and line up the piston rod and planet wheel. Secure the range housing. Torque tighten the bolts.

Note: Insert the guide pins 9996876 into the gearbox housing to facilitate the assembly.

Special tools: 9996479, 9996876, 9996925

Other special equipment: 88890149

Specifications:
110 ± 10Nm

140

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IMPACT 3.0 Wednesday, 14 May 2014

Replace the V-ring on the companion flange. The V-ring must lie flush with the stop on the companion flange.

Note: Check the mating surface of the companion flange to ensure that there is no visible damage.

141

Press the companion flange onto the shaft.

Note: Under no circumstances may the companion flange be heated up or hit with a hammer.
The companion flange must be fitted and pressed onto the output shaft using the specified special tool.
It is of the greatest importance that the companion flange be pressed home completely before the nut is tightened.
If the companion flange is not pressed home properly, the output shaft bearing or the range oil pipe may be damaged.

Special tools: 9992671, 9996222, 9996315, 9996901, 9996925

142

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the counterhold onto the companion flange. Fit a new o-ring and a new nut.
Torque tighten the nut.

Special tools: 9998570

Other special equipment: 1159796

Specifications:
550 ± 50 Nm

143
If the gearbox is equipped with a retarder, perform step144–149. Otherwise go to step150.

144

Fit the retarder with a new O-ring, greased with silicon grease. Guide the bolts into the holes and lower the retarder into
position. Fit the nuts and tighten them by hand as illustrated in the order A, B, C and finally D.
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IMPACT 3.0 Wednesday, 14 May 2014

Torque tighten the nuts in the same order.

Then angle-tighten the nuts 45° in the same order.
Then angle-tighten the nuts another 45° in the same order.

Note: After the retarder has been tightened, there should be a gap between the retarder and the range housing.

Other special equipment: 1159794

Specifications:
30 Nm
45°

145
Turn the gearbox 1/4 turn.

146
Install new O-rings on the heat exchanger and the range housing. Apply silicon grease to the O-rings.

147

Lift up the heat exchanger so that the narrow parts are guided into their respective holes. Fit the securing bolts. Pull the
heat exchanger in with the upper rear screws. Torque tighten the bolts.

Other special equipment: 1159795

Specifications:
85 Nm

148

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the temperature sensor for the retarder.

149

Clamp the retarder wiring.

150

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IMPACT 3.0 Wednesday, 14 May 2014

Install the blocking body, spring and plug for the range function.

151

Install the oil filter housing with a new seal and a new oil filter. Where applicable, fit the oil cooler. Torque tighten the
bolts.

Other special equipment: 88890148

Specifications:
20 ± 3 Nm

152
Turn the gearbox 1/4 turn.

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IMPACT 3.0 Wednesday, 14 May 2014

153

Fit a new gasket between the brake and clutch housing.

154

Add the discs alternately. Begin and end with a steel disc (two friction discs and three steel discs).

155

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the sleeve with a new O-ring, spring and piston.

156

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IMPACT 3.0 Wednesday, 14 May 2014

Fit the cylinder over the disc assembly and torque tighten the screws.

Other special equipment: 88890148

Specifications:
45 ± 5 Nm

157
Clean the nipple threads. Fit the brake pipe. Screw the nuts fully on by hand. Then tighten with a socket spanner a
further 3/4 turn.

158
Fit the clutch cylinder and air hose. Secure the hose with a clip. Torque tighten the bolts.

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IMPACT 3.0 Wednesday, 14 May 2014

Other special equipment: 88890148

Specifications:
45 ± 5 Nm

159
Turn the gearbox 1/4 turn.

160

Fit the magnetic stand and dial gauge on the holder. Check the runout in the sensor wheel. The measuring tip of the
dial gauge must be 2 mm below the teeth. The maximum permitted runout is 0.4 mm.

Special tools: 9999696, 9989876, 9990029

161
Fit a new seal to the control housing.

162

Insert the dowels into the gearbox housing.

Special tools: 9996876

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IMPACT 3.0 Wednesday, 14 May 2014

163

Ensure that the splitter gear clutch ring is in its rearmost position, the 2nd/3rd gear clutch ring is in neutral, the
1st/reverse clutch ring is in its rear position and the range gear is set to high range (with the range shaft in its forward
position and the piston in the range cylinder in its innermost position) and that the shift forks in the control housing are
matched to the clutch rings. This is to enable the control housing to be fitted.

164
Carefully lower the control housing so that no gear teeth are damaged. It is important for the clutch fork for the splitter
gear to enter the clutch ring correctly. Carefully tap the control housing down at the guide pins.

165
Remove the guide pins.

166
Install the control housing screws and torque tighten them diagonally.

Other special equipment: 88890149

Specifications:
110 ± 10Nm

167
Connect VCADS and pressurized air, calibrate the gearbox (40091-3 gear change activation, control housing (for
removal/installation).
Then perform gears test (43116-4 Gears test, gearbox removed) to check that the gearbox is OK.

168
Remove the gearbox from the overhaul stand.

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IMPACT 3.0 Wednesday, 14 May 2014

169
Remove the fixture from the gearbox. Install the valve assembly. Clamp the air hose and electrical wiring.

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