Gearbox, Disassemble-Inspect-Assemble PDF

IMPACT 3.
0 Thursday, 20 September 2012
Chassis ID Path
4/Repair/B12R, AT2512C/Gearbox, disassemble-inspect-assemble. Gearbox removed
Model Identity
B12R 130173225
Publishing Date Operation No.

Saturday, 19 March 2011 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 firstMID 130 PID 160 Parametersetting .
Warning
Always wear safety glasses when using compressed air in the gearbox.
Special tools: 9986485, 9989876, 9990027, 9990028, 9990029, 9990031, 9990120, , 9992000, 9992215, 9992337,
9992613, 9992619 , 9992671, 9996041, 9996042, 9996081, 9996176, 9996222, 9996239, 9996315, 9996479,
9996483, 9996876, 9996889, 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.
The following checks must be carried out during the procedure:
1. Check if axial play possibly has occurred on the main and counter shaft. It must be less than 0.25 mm.
See step58.
2.
Copyright Volvo Group North America

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 / 75
IMPACT 3.0 Thursday, 20 September 2012
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. Refer to step79.
3. Check the distance between the basic housing and the bearing outer race of the main and counter shaft.
Use a feeler gauge with thickness 0.05 mm and maximum width 10 mm. The feeler gauge must not be
possible to insert. See step65.
The following actions must be carried out based on the results of the above checks:
If any of the criteria 1, 2 or 3 are not fulfilled the gearbox must be upgraded to the variant with locking
pins for the bearing's outer races both in the clutch housing and the basic housing. Refer to step 8889
and9596.
If the feeler gauge in criterion 3 can be inserted, the basic housing must also be replaced.
If all criteria 1, 2 and 3 are fulfilled we still recommend that the gearbox is upgraded to the variant with
locking pins for the bearing's outer races both in the clutch housing and the basic housing.
On older gearboxes with long mileages, the existing parts can be refitted and the bearing's 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! 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
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

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1
Clean the outside of the gearbox.
Note: Plug nipples and valves during high pressure washing.

3 / 75
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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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.
Carefully lift the cover and disconnect the cable harness between the cover and control housing.

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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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DD
OD
The figure shows where the various air ducts are that are used to manually operate the control housing air cylinders.

7 / 75
DD
OD

8 / 75
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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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
Check whether the gearbox is in neutral by turning the output shaft companion flange. If it does, blow in the hole for
10 / 75
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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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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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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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.
Special tools: 9986485, 9990031, 9996905, 9999737
18
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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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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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23
If the gearbox is equipped with a retarder, perform step2426. Otherwise go to step27.
24
Remove the retarder's temperature sensor from the heat exchanger or alternatively, remove the connector from the
plate.
25
Remove the retarder wiring cable ties.
26
Remove the three screws securing the heat exchanger and retarder cooler.
27 Copyright Volvo Group North America

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Turn the gearbox so that the output shaft flange faces upwards.
28
Fit counterhold 9998570.

Remove the companion flange nut and O-ring.
29

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Remove the companion flange.
Special tools: 9990084, 9992619, 9992671, 9996156, 9996222, 9998597
30

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Remove the plug, spring and blocking body for the range function. If necessary use a magnet to pull out the blocking
body.
31
32
Remove the four nuts securing the retarder to the range housing (A, B, C and D in the illustration).
33
Carefully lift the retarder away from the gearbox.
34

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Remove the range housing securing screws.
Note: If the gearbox has a retarder, do not forget to remove the screws from the retarder socket.
35
Fit the adapter and lifting eye into the output shaft.
Special tools: 9996479, 9996925
36

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Split the main housing and range housing. Use press tool.
37
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.
38
Remove the oil distributor pipe. Use a socket.
39

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Remove the circlip securing the high range synchronizer.
40
Remove both halves of the washer.
41
Fit both the puller halves on to the high range synchronizer hub.
42

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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
43
Fit the other half of the puller 9998542. Fit the hydraulic pump. Press off the high range synchronizer.
44

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Remove the reversing shaft centre screw.
45
Remove the countershaft cover and shim.
46
Fit the puller and spindle to the reversing shaft.
Special tools: 9996315, 9996917

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47
Fit the hollow drift, hydraulic cylinder and hydraulic pump to the spindle.
Special tools: 9990120, 9992671, 9996222
48
Press out the reversing shaft.
49
Remove the oil pump with the reverse gear pinion.
50

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Fit the shim and the countershaft cover.
51
Fit screw 9996917 on to the main shaft and screw 9996483 on the counter shaft.
Special tools: 9996917, 9996483
52

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Rotate the shafts 20 turns.
53
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
54
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.
55

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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.
56
Turn the gearbox over 1/2 turn.
57
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.
58
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 more, then the clutch housing must be replaced with a new one.
59
60
Remove
Dial indicator 9989876

Magnetic stand 9999696
Bolt 9996917
Bolt 9996483
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Special tools: 9989876, 9999696, 9996917, 9996483
61
Remove the countershaft cover and shim.
62
Remove the main shaft cover and the overdrive's oil pipe, where applicable.
Remove the main shaft shim.
Note: Two alternatives, A and B

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63
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.114
64
Remove the spacer sleeve.
65

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Use feeler gauge with thickness 0.05 mm and maximum width 10 mm to check the gaps.
If the feeler gauge can be inserted, replace the basic housing.
66
Turn the gearbox so that the input shaft faces upwards.
67

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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.
68

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Remove the air hose for the clutch cylinder and the air pipe for the counter shaft brake.
69

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Remove the counter shaft brake.
70

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Remove the piston A and spring B for the counter shaft brake.
71
Remove the clutch housing.
72

36 / 75
Remove the air pipe nipple for the counter shaft brake pipe.
73
Remove the sleeve from the intermediate shaft.
74
Remove the magnet between the clutch housing and the lower part of the basic housing. Clean the magnet.
75

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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
76
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.
77

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Carefully lift out the shaft assembly and place it in the wooden fixture.
78
Remove the lifting tool from the shaft assembly.
79
Check the bearing's outer races for the input shaft and countershaft in the clutch housing. If the outer races are loose
and/or can be rotated at room temperature, then the clutch housing must be replaced.
80

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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
81

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Pull the input shaft's outer race out of the clutch housing. Use a puller, yoke, cylinder, pump and spindle.
Special tools: 88800033, 88800034, 9992671, 9996041, 9996222
82

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Remove the seal for the input shaft. Use a lever.
Note: Replace the seal if necessary.
83

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Drive the outer race of the counter shaft rear bearing out of the gearbox housing. Use a drift and handle.
A= 9992000
B= 9996081
Special tools: 9992000, 9996081
84
Drive the outer race of the main shaft rear bearing out of the gearbox housing. Use a drift and handle.
Special tools: 9992613, 9996176
85
Remove the oil screen and the overflow valve.

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Inspection
86
Clean all parts. 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.
87
Lubricate all parts with gearbox oil before installation.
Assembly
88
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.
Alternatively, for older gearboxes with long mileages, the existing parts can be refitted.
89

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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.
90

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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
91
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.
Special tools: 88800006, 9990028, 9996239, 9996910
92
Carefully lift the shaft assembly into the gearbox housing.
93
Remove the fixture and the three lifting arms from the shafts.
94

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Install the nipple for the air pipe for the counter shaft brake.
95
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
47 / 75
glued in the clutch housing. Use VOLVO glue with part no. 1161370. This alternative is not as reliable as upgrading to
locking pins.
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.
96
Align the groove in the outer races with the marked positions of the lock pins.
97

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Drive the countershaft's outer race into the clutch housing until it reaches the end position.
Special tools: 9992003, 9996041, 9996042, 9992671, 9996222
98

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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
99
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.
100
Place the clutch housing on the basic housing. Check that the guide pins locate in the holes in the clutch housing.
101
Fit the clutch housing screws and torque tighten them alternately.
Specifications:
110 10 Nm
102

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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.
103
104

51 / 75
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.
105

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Fit the main shaft's cover with the shim.

Torque tighten the screws diagonally.
Note: When replacing the cover (two alternatives, A and B), use new screws.
Specifications:
405 Nm
106

53 / 75
Install a shim with thickness approximately 0.9 mm.
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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Fit the countershaft's cover with the shim.

Note: When replacing the cover, use new screws.
Specifications:
405 Nm
108
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.
109
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Fit screw 9996917 on the main shaft and screw 9996483 on the counter shaft.
Special tools: 9996917, 9996483
110
111

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Attach the dial gauge to the magnetic stand. The tip of the dial gauge should touch the sun wheel. Zero the dial gauge
Special tools: 9989876, 9999696
112
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.
113
Turn the gearbox 1/2 turn.

Remove the main shaft cover.
114

57 / 75
When replacing the spacer sleeve, reuse the piston rings with the new spacer sleeve.
115
Fit the spacer sleeve.
Special tools: 9996222, 9992671, 88800246, 9996315, 9996917
116

58 / 75
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.
117

59 / 75
Fit the main shaft's cover with the shim.

Specifications:
405 Nm
118
119

60 / 75
Attach the dial gauge to the counter shaft. The tip of the dial gauge should touch the counter shaft. Zero the dial gauge
120
121
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.
122
123
Remove
Dial indicator 9989876

Magnetic stand 9999696
Bolt 9996917
Bolt 9996483
Special tools: 9989876, 9999696, 9996917, 9996483

61 / 75
124
Remove the countershaft's cover.
125
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
62 / 75
pretensioning of between 0.1 and 0.2 mm.
126
Fit the countershaft's cover with the shim.
Note: Torque tighten the screws diagonally.
Specifications:
405 Nm
127

63 / 75
Fit a new gasket on the oil pump.
128
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.
Specifications:
488 Nm
129
Where applicable fit the overdrive oil pipe.
130

64 / 75
Press in the synchronizer for high range.
Special tools: 9990015, 9992671, 9996081, 9996022, 9996315, 9998542
131
Fit both the washer halves.
132
Fit the high range circlip.

65 / 75
Note: The circlip is available in seven thicknesses. Choose the thickest circlip that assures a residual play of maximum
0.05 mm.
133
Remove the forks 9990029 holding the clutch sleeves in place.
134
Oil and fit new O-rings. Install the oil distribution piping. Torque tighten the oil distribution piping. Use a socket.
Specifications:
250 35 Nm
135

66 / 75
Apply VOLVO approved high-temperature liquid gasket.
136
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
Specifications:
110 10Nm
137
67 / 75
138
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.
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.
Specifications:
30 Nm
45
139
140
Install new O-rings on the heat exchanger and the range housing. Apply silicon grease to the O-rings.
141

68 / 75
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.
Specifications:
85 Nm
142
Fit the temperature sensor for the retarder.
143
Clamp the retarder wiring.
144

69 / 75
Install the blocking body, spring and plug for the range function.
145
Install the oil filter housing with a new seal and a new oil filter. Where applicable, fit the oil cooler. Torque tighten the
bolts.
Specifications:
20 3 Nm
146
147

70 / 75
Fit a new gasket between the brake and clutch housing.
148
Add the discs alternately. Begin and end with a steel disc (two friction discs and three steel discs).
149

71 / 75
Fit the sleeve with a new O-ring, spring and piston.
150

72 / 75
Fit the cylinder over the disc assembly and torque tighten the screws.
Specifications:
45 5 Nm
151
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.
152
Fit the clutch cylinder and air hose. Secure the hose with a clip. Torque tighten the bolts.
Specifications:
73 / 75
45 5 Nm
153
154
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
155
Fit a new seal to the control housing.
156
Insert the dowels into the gearbox housing.
157

74 / 75
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.
158
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.
159
Remove the guide pins.
160
Install the control housing screws and torque tighten them diagonally.
Specifications:
110 10Nm
161
Connect VCADS, calibrate the gearbox and select perform test to check that the gearbox is working properly.
162
Remove the gearbox from the overhaul stand.
163
Remove the fixture from the gearbox. Install the valve assembly. Clamp the air hose and electrical wiring.

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What are the steps involved in disassembling the gearbox?

What are the steps involved in disassembling the gearbox?

What checks need to be performed before disassembling the gearbox?

What checks need to be performed before disassembling the gearbox?

IMPACT 3.

0 Thursday, 20 September 2012

Publishing Date Operation No.

43187-4 Gearbox, disassemble-inspect-assemble

Other special equipment: 88890148, 88890149

The following checks must be carried out during the procedure:

Copyright Volvo Group North America

Clutch housing with locking pins

Copyright Volvo Group North America

Note: Plug nipples and valves during high pressure washing.

Copyright Volvo Group North America

Copyright Volvo Group North America

Copyright Volvo Group North America

Copyright Volvo Group North America

Copyright Volvo Group North America

Copyright Volvo Group North America

Copyright Volvo Group North America

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

Copyright Volvo Group North America

Copyright Volvo Group North America

Special tools: 9986485, 9990031, 9996905, 9999737

Drain the gearbox oil.

Copyright Volvo Group North America

Remove the oil filter cover and guide sleeve.

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

Special tools: 9992337

Copyright Volvo Group North America

Remove the retarder wiring cable ties.

27 Copyright Volvo Group North America

Fit counterhold 9998570.

Special tools: 9998570

Copyright Volvo Group North America

Remove the companion flange.

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

Copyright Volvo Group North America

Copyright Volvo Group North America

Remove the range housing securing screws.

Special tools: 9996479, 9996925

Copyright Volvo Group North America

Special tools: 9998051

Remove the oil distributor pipe. Use a socket.

Special tools: 9990027

Copyright Volvo Group North America

Remove the circlip securing the high range synchronizer.

Remove both halves of the washer.

Special tools: 88800015

Copyright Volvo Group North America

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

Special tools: 9996222

Copyright Volvo Group North America

Remove the reversing shaft centre screw.

Remove the countershaft cover and shim.

Fit the puller and spindle to the reversing shaft.

Special tools: 9996315, 9996917

Special tools: 9990120, 9992671, 9996222