IMPACT 4.04.

00 13/04/2023

Chassis ID Path
4311/Description, Design and function//Gearbox, mechanical, component description

Model Identity
FM (4) 139085721

Publish date ID/Operation

23/05/2017

Gearbox, mechanical, component description

Gearbox mechanical, component description
General
Housings
Internal parts
Input shaft
Intermediate shaft
Main Shaft
Output shaft
Reverse shaft and gear

Synchronization
Range gear
Gearbox selection
Drive line for Direct-Drive gearbox
Drive line for Over-Drive gearbox

Compressed air system

Range gear control
Splitter control
Shift lock control

Electrical components
Lubrication
Ventilation
Evaporator

Related information

Gearbox mechanical, component description

General
The gearbox is a splitter and range gearbox with 12 fully-synchronized gears, 2 unsynchronized
crawler gears (forward) and 4 unsynchronized reverse gears.
The main parts of this gearbox are:
● A basic gearbox section with 3 synchronized gears

● Integrated crawler and reverse gears

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.

1 / 61
IMPACT 4.04.00 13/04/2023

● A range gear

● A splitter gear

Retarder variants

Variant symbol Variant description

RET-TH Transmission mounted hydrodynamic retarder

URETARD Without retarder

Power steering system variants

Variant symbol Variant description

PSS-SING Power steering system single (steering pump engine driven)

PSS-DUAL Power steering system dual (emergency steering pump gearbox driven)

Power take-off variants

Variant symbol Variant description

PTR-FL Gearbox driven low speed PTO with SAE drive flange

PTR-F Gearbox driven medium speed PTO with SAE drive flange

PTR-FH Gearbox driven high speed PTO with SAE drive flange

Gearbox driven low speed PTO with DIN connection for

PTR-D
directly mounted hydraulic pump

Gearbox driven medium speed PTO with DIN connection for

PTR-DM
directly mounted hydraulic pump

Gearbox driven high speed PTO with DIN connection for

PTR-DH
directly mounted hydraulic pump

Gearbox driven double PTO with SAE drive flange and DIN
PTRD-F
connection for directly mounted hydraulic pump

Gearbox driven high speed double PTO with two DIN

PTRD-D
connections for directly mounted hydraulic pumps

Gearbox driven high speed double PTO with SAE drive

PTRD-D1 flange and DIN connection for directly mounted hydraulic
pump

Gearbox driven high speed double PTO with two SAE drive
PTRD-D2 flanges and DIN connection for directly mounted hydraulic
pump

UPTOTR Without gearbox driven PTO

Gearbox, overview

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 / 61
IMPACT 4.04.00 13/04/2023

1 Clutch housing

2 Main housing

3 Range housing

4 Main shaft

5 Intermediate shaft

6 Reverse shaft

7 Oil pump gear wheel

8 Planetary gearing

9 Control housing

10 Speed sensor

11 Shift rod

12 Input shaft

13 Output shaft

14 Cross-tooth flange

Identification plate

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.

3 / 61
IMPACT 4.04.00 13/04/2023

1 Component designation

2 Spare part number

3 Service category

4 Factory part number

5 Serial number

The type plate is mounted on the left-hand side of the clutch housing.

Serial number description

2003 Year of manufacture

36 Week of manufacture

1 Day of the week

0001 Manufacturing order number

Terminology

Note
This table is a specific example for variant VTO2514B.

Type VTO2514B

VT - Volvo Transmission
O - Overdrive
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.

4 / 61
IMPACT 4.04.00 13/04/2023

Symbols 25 - Maximum torque (2450 Nm)

14 - Number of forward gears
B - 2nd version

Housings

Housings

1 Clutch housing

2 Main housing

3 Range housing

4 Control housing

The main sections of the gearbox are the clutch housing (1), main housing (2), range housing (3) and
control housing (4). The main housing is cast from grey iron, whereas the clutch housing, range
housing and control housing are cast from aluminium.
The clutch housing (1) contains the input shaft as well as the clutch servo.
The main housing (2) contains the main shaft, intermediate shaft, reverse shaft and shift mechanism.
The splitter gear is located in the front section of the main housing.
The range housing (3) contains the planetary gearing and shift mechanism, actuator and output shaft.
Furthermore, there is a connection flange for power take-off and emergency steering servo pump at
the rear of the housing.

Internal 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.

5 / 61
IMPACT 4.04.00 13/04/2023

Internal parts

1 Shift rod, 3rd gear shifting fork

2 Shift rod,1st and 2nd gear shifting fork

3 Shift rod, crawler and reverse gear shifting fork

4 Shift rod, splitter gear shifting fork

5 Input shaft

6 Splitter gear (low split)

7 Splitter and 3rd gear (High split and basic 3rd gear)

8 1st gear

9 2nd gear

10 Crawler gear

11 Reverse gear

12 Sun gear

13 Intermediate shaft

14 Oil pump gear

15 Reverse gear

16 Reverse shaft

17 Planetary gearing

18 Output shaft

19 Cross-tooth flange

20 Range gear shifting fork

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.

6 / 61
IMPACT 4.04.00 13/04/2023

Input shaft
The input shaft, which transfers the engine power to the gearbox via the clutch disc, is mounted in the
clutch housing in conical roller bearings. The gear wheel runs on a needle bearing.

Note
The input shaft always rotates in a clockwise direction (viewed from the front).

Intermediate shaft
The intermediate shaft is mounted in conical roller bearings in the clutch housing and the rear end of
the main housing. The splitter gears (first two gears at the front of the shaft) are pressed onto the
intermediate shaft and the other gears are an integral part of the shaft.

Main Shaft
Both ends of the main shaft are mounted in conical roller bearings. The front end is mounted in the
end of the input shaft, whereas the rear end is mounted in the rear of the main housing. All the gears
on the input shaft run on needle bearings.
All the basic gears, their synchronizers, and crawler and reverse idler gears are mounted on the main
shaft. The reverse and crawler gears are not synchronized. The sun gear for the range planet gears
is pressed onto the rear end of the main shaft.

Output shaft
The output shaft is mounted in the range housing with roller bearing and is linked to the range gear.

Note
The cross-tooth flange is standard for all types of gearbox.

Reverse shaft and gear

The reverse shaft is suspended (between a spacing sleeve) in the main housing. The reverse gear
runs on a needle bearing and changes the direction of rotation of the main shaft, which allows the
vehicle to reverse.The driven shaft passes through the reverse shaft to the oil pump. The driven shaft
is mounted on needle bearings and is permanently engaged with the gear wheel for 2nd gear on the
intermediate shaft.

Synchronization

Basic synchronization

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.

7 / 61
IMPACT 4.04.00 13/04/2023

1 Engaging ring

2 Inner cone

3 Double cone

4 Outer cone

5 Pusher plate

6 Disc spring

7 Guide sleeve

8 Engaging sleeve

9 Spring-loaded detent pin(4)

10 Spring-loaded detent pin for neutral (2)

A mechanical servo function provides extra power during synchronization, which makes gear change
easier. This design allows the turning torque, which is created when the synchronizer begins to
reduce the rotation speed, to be converted to axial power. This automatically provides the driver with
mechanical servo assistance.
The act of changing gear can be divided into five phases:
● Neutral:
■ The engaging sleeve (8) is kept in a neutral position, in relation to the guide sleeve (7),
using spring-loaded detent pins (10). In this position, no axial power is transferred to the
outer cone (4).

● Blocking:
■ The shifter fork acts on the engaging sleeve (8), which pushes the stops against the outer
cone (4). This causes an increase in friction. The friction between the conical surfaces
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.

8 / 61
IMPACT 4.04.00 13/04/2023

causes the inner cone (2) and outer cone (4) to rotate in the same direction as the double
cone (3) until the outer cone meets the lug on the guide sleeve (7). The lug surface on the
outer cone connects with the engaging sleeve (8). The angle of the lug surface is designed
specifically to prevent axial motion of the engaging sleeve until synchronization is complete.

● Synchronization:
■ The friction between the conical surfaces causes the rotational speeds of the double, inner
and outer cones to equalize. Since the engaging sleeve (8) is in the blocked position, it
cannot be moved axially and the disc spring (6) is depressed. This provides extra power to
the engaging sleeve via the pusher plate (5).

● Release:
■ Synchronization is complete once the double cone (3) rotates at the same speed as the
inner (2) and outer cones (4). The block surface is now released and the engaging sleeve (8
) can move axially.

● Gear engaged:
■ The teeth on the engaging sleeve (8) now interlock with the teeth on the engaging ring (1)
and shifting is complete.

Split synchronization

1 Brass pin

2 Engaging sleeve

3 Synchronizing cone

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.

9 / 61
IMPACT 4.04.00 13/04/2023

4 Engaging ring

5 Guide sleeve

6 Spring-loaded detent pin

A Neutral position

B Synchronization

C Gear engaged

The split synchronizer is, by design, a single synchronizer.The purpose of the synchronizer is to
equalize the speeds of the free running gears and the shaft in order to connect them.
Function:
● Neutral position (A):
■ The engaging sleeve (2) is kept in a neutral position, in relation to the guide sleeve (5) using
spring-loaded detent pin (6). There is a layer of oil between the conical surfaces of the
synchronizing cone (3) and the engaging ring (4). The free running gear with engaging ring
on the input shaft and the input shaft rotate at different speeds.

● Synchronization (B):
■ The shifting fork acts on the engaging sleeve (2) via the brass pin (1), which pushes the
synchronizing cone (3) against the engaging ring (4). The friction produced equalizes the
speeds of the guide sleeve (5) and the engaging ring (4).

● Gear engaged (C):

■ Once these two parts are moving at the same speed, the engaging sleeve (2) can
interconnect with the engaging ring (4). The gear then interlocks with the input shaft via the
guide sleeve (5), and the power from the engine is transferred through the drive line.

Range gear

Range gear

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.

10 / 61
IMPACT 4.04.00 13/04/2023

1 Main shaft

2 Sun gear

3 Ring gear

4 Planetary gears

5 Planetary gears holder

6 Output shaft

7 Clutch sleeve

8 Piston rod with shifting fork

A High range

B Low range

The range gear comprises a planetary gearing system with two gear ratios, low range and high
range. In the high-range position, power is transferred directly to the driven wheels. In the low-range
position, gear reduction is achieved using the planetary gears.
The planetary gearing includes five planetary gears (4), which are in contact with the sun gear (2).
The planetary gears (4) are contained in a planetary gears holder (5). Around the planetary gears sits
the ring gear (3), which is connected to the clutch sleeve (7). The planetary gears holder (5) and the
output shaft (6) are connected by splines. The output shaft is mounted in a ball bearing at the rear
end of the range housing.
Shifting between high and low range is achieved by a pneumatic range cylinder, which acts on a
shifting fork (8). The shifting fork acts in turn on the clutch sleeve, which is attached to the ring gear.
● Planetary gear function in high range

When shifting to high range, the clutch sleeve (7) is moved in the direction of the main shaft (1). In
the high range position, the ring gear (3) is released from the range housing. The planetary gears (4)
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.

11 / 61
IMPACT 4.04.00 13/04/2023

are locked against the planetary gears holder (5), and the entire planetary gearing system rotates as
a single unit. The main shaft (1) and the output shaft (6) both rotate at the same speed.

Note
Gear ratio 1:1.

● Planetary gear function in low range

When shifting to low range, the clutch sleeve (7) is moved in the direction of the output shaft (6). In
the low range position, the ring gear (3) is locked to the range housing, and the planetary gears (4)
are forced to rotate with the sun gear (2). The output shaft (6) then rotates at a lower speed than the
main shaft (1).

Note
Gear ratio 3.75:1.

Gearbox selection

Control 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.

12 / 61
IMPACT 4.04.00 13/04/2023

1 Control housing

2 Neutral position switch

3 Reverse position switch

4 Inhibitor valve

5 Damping compound

6 Reverse position detent

7 Stop cylinder

8 First gear inhibitor solenoid

9 Arm

10 Lever arm

11 Cover

12 Bar

13 Lever arm

14 Side control 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.

13 / 61
IMPACT 4.04.00 13/04/2023

15 Blocking cam 1st gear

16 Gear selector

17 Cam/Gear position detent

18 Gear position detent

A-A Cam/Gear position detent cross-section

The control housing is cast from aluminium and is intended to transfer the motion of the gear lever to
the gearbox shift rods. The position of the control housing can be adjusted for both left and right-hand
drive truck variants.

Note
An air filter, placed on the inhibitor cylinder cover on the control housing, purifies the air
entering the pneumatic shifting system.

Gearshift cable

The cable gear shift system has two selector cables, which transfer force between the gear lever and
the control housing on the gearbox.
The cables are both push-pull wires. The system uses one cable for lengthways movement and one
for sideways movement. They are not adjustable. In order to maintain good gear changing quality,
there is rubber damping at each end. The attachment system has a quick-release mechanism.
The wire-cabling attachment system is colour-coded:
● Black: select stroke, gear lever

● White: shift stroke, gear lever

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 / 61
IMPACT 4.04.00 13/04/2023

● Blue: shift stroke, control housing

● Orange: select stroke, control housing

Drive line for Direct-Drive gearbox

Crawler Low Split

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.

15 / 61
IMPACT 4.04.00 13/04/2023

Crawler High Split

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 / 61
IMPACT 4.04.00 13/04/2023

1st gear Low Split

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.

17 / 61
IMPACT 4.04.00 13/04/2023

1st gear High Split

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.

18 / 61
IMPACT 4.04.00 13/04/2023

2nd gear Low Split

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.

19 / 61
IMPACT 4.04.00 13/04/2023

2nd gear High Split

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.

20 / 61
IMPACT 4.04.00 13/04/2023

3rd gear Low Split

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.

21 / 61
IMPACT 4.04.00 13/04/2023

3rd gear High Split

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.

22 / 61
IMPACT 4.04.00 13/04/2023

4th gear Low Split

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.

23 / 61
IMPACT 4.04.00 13/04/2023

4th gear High Split

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.

24 / 61
IMPACT 4.04.00 13/04/2023

5th gear Low Split

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.

25 / 61
IMPACT 4.04.00 13/04/2023

5th gear High Split

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.

26 / 61
IMPACT 4.04.00 13/04/2023

6th gear Low Split

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.

27 / 61
IMPACT 4.04.00 13/04/2023

6th gear High Split

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.

28 / 61
IMPACT 4.04.00 13/04/2023

Reverse Low Range Low Split

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.

29 / 61
IMPACT 4.04.00 13/04/2023

Reverse Low Range High Split

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.

30 / 61
IMPACT 4.04.00 13/04/2023

Reverse High Range Low Split

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.

31 / 61
IMPACT 4.04.00 13/04/2023

Reverse High Range High Split

Drive line for Over-Drive gearbox

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.

32 / 61
IMPACT 4.04.00 13/04/2023

Crawler Low Split

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.

33 / 61
IMPACT 4.04.00 13/04/2023

Crawler High Split

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.

34 / 61
IMPACT 4.04.00 13/04/2023

1st gear Low Split

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.

35 / 61
IMPACT 4.04.00 13/04/2023

1st gear High Split

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.

36 / 61
IMPACT 4.04.00 13/04/2023

2nd gear Low Split

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 / 61
IMPACT 4.04.00 13/04/2023

2nd gear High Split

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 / 61
IMPACT 4.04.00 13/04/2023

3rd gear Low Split

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.

39 / 61
IMPACT 4.04.00 13/04/2023

3rd gear High Split

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.

40 / 61
IMPACT 4.04.00 13/04/2023

4th gear Low Split

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.

41 / 61
IMPACT 4.04.00 13/04/2023

4th gear High Split

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.

42 / 61
IMPACT 4.04.00 13/04/2023

5th gear Low Split

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.

43 / 61
IMPACT 4.04.00 13/04/2023

5th gear High Split

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.

44 / 61
IMPACT 4.04.00 13/04/2023

6th gear Low Split

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.

45 / 61
IMPACT 4.04.00 13/04/2023

6th gear High Split

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.

46 / 61
IMPACT 4.04.00 13/04/2023

Reverse Low Range Low Split

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.

47 / 61
IMPACT 4.04.00 13/04/2023

Reverse Low Range High Split

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.

48 / 61
IMPACT 4.04.00 13/04/2023

Reverse High Range Low Split

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.

49 / 61
IMPACT 4.04.00 13/04/2023

Reverse High Range High Split

Compressed air system

Compressed air system

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.

50 / 61
IMPACT 4.04.00 13/04/2023

1 Range cylinder

2 Split cylinder

3 Range inhibitor valve

4 Control housing inhibitor valve

5 Split inhibitor valve

6 Stop cylinder

7 Range relay valve

8 Split relay valve

9 Range inhibitor solenoid

10 Air filter

11 Gear lever

Range cylinder
● The range cylinder (1) is a double-action air cylinder fitted at the rear end of the control housing.
Its purpose is to shift the range gear between low and high range positions.

Split cylinder
● The split cylinder (2) is a double-action air cylinder fitted in the clutch bell housing. Its purpose is
to shift the spilt synchronizer between the low and high split positions.

Range inhibitor valve

● The range inhibitor valve (3) operates the stop cylinder (see description of stop cylinder (6)).

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.

51 / 61
IMPACT 4.04.00 13/04/2023

Control housing inhibitor valve

● The control housing inhibitor valve (4) prevents range changing if any of the gears in the gearbox
are engaged.

Split inhibitor valve

● The split inhibitor valve (5) prevents split gear changing from occurring without the clutch pedal
being depressed.

Stop cylinder
● The stop cylinder (6) is a double-action air cylinder. Its first function is to lock the basic gearbox
in neutral position when range changing. Its second function is to lock the gear lever to prevent
from being engaged if the clutch pedal is released.

Range relay valve

● The range relay valve (7) directs the air flow to either side of the range cylinder piston depending
on which gear is engaged.

Split relay valve

● The split relay valve (8) directs the air flow to either side of the split cylinder piston depending on
which gear is engaged.

Range inhibitor solenoid

● The range inhibitor solenoid (9) cuts off air supply to the range relay valve when shifting from
high to low range if the vehicle speed is above about 30 km/h.

Air filter
● The air filter (10) is located in the feed pipe of the pneumatic system on the cover of the stop
cylinder (6). Its purpose is to protect the gearbox compressed air system against impurities.

Gear lever
● The gear lever (11) has two switches, one at the front for range selection and one on the side for
split selection.
The Gear lever contains control valves for range and split gear changing. By changing the range
or split gear switch position, the control valves provide or cut off air supply to the range or split
cylinder relay valve (7) or (8).

Range gear control

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.

52 / 61
IMPACT 4.04.00 13/04/2023

When shifting from high to low range, the valve in the gear lever opens and air flows into the solenoid
valve (9) and the relay valve (7) if the speed is below approximately 30 km/h. Shifting occurs when
the gear lever passes neutral. The check valve (4) opens and air flows via the relay valve (7) to the
range cylinder. The check valve (3) opens and once again blocks the basic gearbox in neutral with
the lock cylinder (6) .

Splitter control

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.

53 / 61
IMPACT 4.04.00 13/04/2023

The inhibitor valve (5) is integrated in the clutch servo and controls the split gear. When shifting from
low to high split, the valve opens in the gear lever and air flows to the relay valve (8) . Shifting occurs
when the clutch pedal is fully depressed, the inhibitor valve (5) opens and the splitter control cylinder
(2) operates.

Shift lock control

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.

54 / 61
IMPACT 4.04.00 13/04/2023

When the gear lever is in neutral and the clutch is released, the control is blocked by the spring
loaded plunger in the stop cylinder (6) . When the clutch is depressed, the air flows from the split
inhibitor valve (5) to the bottom of the cylinder and overcomes the spring force, making it possible to
engage the gear. This function prevents shifting when the clutch is released.

Electrical components

Electrical components

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.

55 / 61
IMPACT 4.04.00 13/04/2023

1 Neutral position switch

2 Reverse position switch

3 First gear inhibitor solenoid

4 Range gear position switch

5 Range inhibitor solenoid

6 Speed sensor

7 Oil temperature sensor

8 Split gear position switch

Neutral position switch

● The neutral position switch (1) is used for functions such as Cruise Control, PTO, Parking brake
and Auxiliary Brake.

Reverse position switch

● The reverse position switch (2) sends a signal to activate the reversing lights when reverse gear
is engaged.

First gear inhibitor solenoid

● The first gear inhibitor solenoid (3) prevents the driver from engaging 1st gear when the vehicle
speed is too high. The purpose of this is to protect the engine and the clutch against over
revving. To activate this function, the following conditions must be met:
■ Low range position

■ Speed is over 20 km/h

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.

56 / 61
IMPACT 4.04.00 13/04/2023

Range gear position switch

● The range gear position switch (4) provides the CCIOM control unit with information regarding
the range position, allowing the first gear inhibitor solenoid to be activated if shifting to a wrong
gear is attempted.

Range inhibitor solenoid

● The range inhibitor solenoid (5) prevents the driver changing down to low range when the
vehicle speed exceeds about 30 km/h. It is controlled by the CCIOM control unit.

Speed sensor
● The speed sensor (6) sends a signal to the VMCU control unit.

Oil temperature sensor

● The oil temperature sensor (7) sends a signal to the CCIOM control unit in order to display the
gearbox oil temperature on the instrument panel.

Split gear position switch

● The split gear position switch (8) sends a signal to the CCIOM control unit to light up the split
lamp on the instrument panel when low split is engaged.

Lubrication

Lubrication

1 Oil strainer

2 Oil distribution channels

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.

57 / 61
IMPACT 4.04.00 13/04/2023

3 Oil pump

The gearbox is lubricated through a combination of pressure and splash.

The gearbox has an integral circulation system. The oil is drawn up from the bottom of the gearbox
through the strainer (1) by the oil pump (3), which is driven by the intermediate shaft.
The oil is pumped via the rear main shaft cover and distribution channels (2) in the main shaft to the
bearings, on the input shaft, main shaft and range gear. The channels then direct the oil to the
synchronization bearings and parts.
Gearboxes with Overdrive have an extra oil pipe from the rear main shaft cover to the Overdrive gear.
Approximately 30% of the oil is distributed to the main shaft and the remaining 70% to the range
gear.

Oil pump

1 High pressure by-pass valve

2 Clogged filter by-pass valve

3 Stay tube

4 Oil filter

5 Cover

6 Oil cooler (optional)

The oil pump is an eccentric pump that is driven by the countershaft via a gearwheel and a driven
shaft which passes though the reverse shaft. This shaft runs on two needle bearing in the reverse
shaft.
The pump has two by-pass valves. The first (1) ensures that the gearbox is lubricated if the filter
becomes clogged, and the second (2) protects against high pressure in the system (e.g. cold start).
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.

58 / 61
IMPACT 4.04.00 13/04/2023

The valves are located in the pump housing and comprise a compression spring and valve cone.
There is a full flow filter (3) in the housing on the housing on the pressurized side of the pump. The
filter is accessible from the outside and is protected by a cover (4) on the range housing. There is a
stay tube (5) in the oil filter, which prevents the filter from collapsing.
An oil cooler (6) is available for the gearbox (as optional). Coolant is supplied from the engine cooling
system to the oil cooler heat exchanger via pipes and hoses.

Oil level

1 Filling plug

2 Venting hose

3 Level plug

4 Draining plug

The drain plug (4) is located on the lower side of the gearbox. After draining, fill the gearbox with oil
through the plug (1) on the top side of the gearbox.
After filling-up the gearbox, check the oil level through a transparent plug (3).

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.

59 / 61
IMPACT 4.04.00 13/04/2023

Note
The oil level must be between the MAX and the MIN marks.

The venting hose (2) is mounted on the filling plug (1) through an elbow nipple. During driving, oil
heats up inside the transmission. The venting system prevents air pressure buildup within the
gearbox.

Ventilation

The gearbox is vented to prevent excessive pressure build-up, for example during cold start.
There are two types of ventilation system:
● A: Oil mist inside the gearbox vents out through a hose (2) mounted on the filling plug with
incorporated elbow nipple (1) .

● B: Oil mist inside the gearbox vents out through a pipe mounted on the filling plug with
incorporated elbow nipple (1) . The pipe is connected to an evaporator (3) which is also
connected to the stop valve (4) at the gearbox control housing.

Evaporator

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.

60 / 61
IMPACT 4.04.00 13/04/2023

The evaporator separates micro particles from the oil mist in the following process:
1 The oil mist with its micro particles moves from the gearbox housing and into the evaporator's
lower chamber because of the higher pressure in the gearbox.

2 The oil mist in the lower chamber moves to the upper chamber because of its higher
temperature.

3 Highly pressurized air from the stop valve at the gearbox control housing is released and
pressed into the upper chamber of the evaporator when the driver is shifting gear.

4 The oil mist that contains micro particles is pressed into to the lower chamber. In this process
the micro particles are separated from the oil mist.

5 The oil mist in the lower chamber is moving back into the upper chamber.

6 The micro particles fall down and out through an opening in the lower chamber.

This process is continuously repeated.

Related information
Component description
➠ Clutch, component description
➠ Hydraulic retarder, component description
System descriptions
➠ Vehicle electronics overview, system description
➠ APM, component description
➠ Air supply, system description

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.

61 / 61