Range Gear, Overhaul PDF

IMPACT 3.
0 Thursday, 20 September 2012
Chassis ID Path
4/Repair/B12R, AT2412C/Range gear, overhaul. Unit removed
Model Identity
B12R 128875322
Publishing Date Operation No.

Saturday, 27 February 2010 43175-5
43175-5 Range gear, overhaul

Unit removed
As the same illustrations are reused for different variants, some details may differ for the variant you are working on.
The essential information in the illustrations is, however, always correct.
Disassembly
Assembly
Special tools: 9988185, 9990084, 9992241, 9992619, 9992631, 9992671, 9994078, 9996156, 9996222, 9996315 ,
9996479, 9996759, 9996788, 9996901, 9996925, 9998542, 9998570, 9998575, 9998597, 88800026 , 88800174,
88800246, 9996917
Other special equipment: 1159794, 1159795
Range gear overview
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.
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IMPACT 3.0 Thursday, 20 September 2012
A. Engaging ring, high range

B. Engaging ring, low range
C. Synchroniser ring
D. Ring spring
E. Ring gear
F. Selector fork
G. Planetary gear
H. Retarder drive gear
Disassembly
1
Remove.
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Special tools: 9996479, 9996925
2
Remove the emergency steering servo pump, if fitted.
Special tools: 9994078

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Remove the circlip.

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Remove the range gear.

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Note: Make sure that the planetary gear is free and that it does not fall onto the floor or pressing table and get
damaged.
9
Remove the planetary gear from the press.
10
Press out the output shaft bearing.
11
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If the vehicle is equipped with a retarder, perform steps 12 - 13.

Otherwise go to step 14.
12
Remove the circlip for the retarder drive.
13
Press off the retarder gear drive.
Note: For a 70 mm shaft, use 88800026.

For an 80 mm shaft use 88800183 up to chassis number -202738 and 88800195 from chassis number 202739- with
fabrication number 20064830171.
Special tools: 9992671, 9996222, 9998542, 88800026, 88800183, 88800195
14

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Remove the selector fork.

Check the brass dowels.
Replace the brass dowels if they are damaged or worn.
For replacement see 43262-4 Brasspin selector fork, replace (all) .
15

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To ensure correct operation, it is important that the markings on the synchronising ring (A) line up with a
chamfered (angled) tooth on the ring gear (B) as illustrated.
Marking XXXXXXXX shows the part number.
16
Remove the low range engaging ring (B), synchroniser ring (C) and ring spring (D) from ring gear (E).
17

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Check the planetary gear. The planetary gear must be replaced if damaged, abnormally worn, or if there is an axial
play of more than 1.3 mm.
Specifications:
1.3 mm
18
Clean all components.
Note: Do not wash the engaging rings.
19

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Inspect the wear surfaces on the high range engaging ring (A), low range engaging ring (B) synchroniser ring (C) and
ring gear (E).
Rings with fully or partially worn grooves and rings with blued surfaces must be replaced.
Check the engaging teeth.
Warning
When ordering one of the components high range engaging ring (A), low range engaging ring (B) or
synchroniser ring (C), if a kit containing all three components (A, B, C) is delivered, all three components
must be replaced.
20
Remove the oil return pipe. Use wrench 9990027.

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21
Remove the circlip.
22
Remove the washer.
23
Install the puller rings 88800015.
24

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Install one half of puller 9998542 on puller rings 88800015, together with the hydraulic cylinder 9992671, spindle
9992619 and drift 9996889.
Note: Check that the divide in the puller rings 88800015 is at 90 to the divide in puller 9998542.
Special tools: 88800015, 9998542, 9992671, 9996889, 9998542
Specifications:
90
25
Install the other half of puller 9998542 and hydraulic pump 9996222.
Remove the high range engaging ring.
Special tools: 9998542, 9996222
26

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Check the part no. of the spacer sleeve and check TPI 431-033 in parts information.
If necessary, replace the spacer sleeve according to steps 27 - 29.
27
Remove the old spacer sleeve.
Assembly
28

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Transfer the piston rings to the new spacer sleeve.
29
Fit the new spacer sleeve.
Special tools: 9996917, 88800246, 9992671, 9996315, 9996222
30

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Press in a new high range engaging ring.
Special tools: 9990015, 9992671, 9996081, 9996022, 9996315, 9998542
31
Fit the washer.
32
Fit the locking ring

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33
Fit the oil return pipe.
34
Clean old sealant off the range housing.
35
Lubricate sliding surfaces and O-rings with transmission fluid during assembly.
36
It is important to lubricate the carbon fibre lining on synchroniser ring (C).
37
If the vehicle is equipped with a retarder, perform step 38.
38

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Press on the retarder gear drive. Fit the drive gear circlip.
Note: For a 70 mm shaft, use 88800026.

For an 80 mm shaft use 88800183 up to chassis number -202738 and 88800195 from chassis number 202739- with
fabrication number 20064830171.
Special tools: 9992631, 9998542, 88800026
39
Press home a new bearing in the range housing.

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40
Fit the thickest possible circlip for the bearing. The maximum permitted play is 0.1 mm.
Use a feeler gauge to measure the play.
Specifications:
max 0.1 mm
41
Place the planet gear in the press and lift on the range housing.
42

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Press on the bearing in the range housing on the output shaft.
Note: Check that the range gear drive shaft does not lock in the range gear housing.
43

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Fit the pole wheel.

Fit the vehicle speed sensor with an undamaged gasket.
Tighten the speed sensor.
Other special equipment: 1159794
Specifications:
255 Nm
44
Place the sealing ring on the drift and install it in the range gear housing. See item 45 or item 46.
Note: Fill the space between the sealing lips to 1/3 with a Volvo approved grease for low temperature use.
45
Shaft 70 mm diameter
For a 70 mm shaft, use 9998575.
Specifications:
70 mm
46

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Shaft 80 mm diameter
For an 80 mm shaft, use 88800174. The ring belonging to tool 88800174 must only be used in VT gearboxes.
Specifications:
80 mm
47

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Assemble the synchronising ring, ring spring and ring gear.
Note: Make sure that the markings on the synchronising ring (A) lines up with a chamfered (angled) tooth on
the ring gear (B) as illustrated.
This is vital to ensure correct operation.
Marking XXXXXXXX on the synchroniser ring (A) shows the part number.
48

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Fit the engaging ring and selector fork on the ring gear.
49
Fit the package in the range housing. Torque tighten the bolts diagonally.
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Note: If a new range housing has been fitted, self-tapping screws must be used in the holes. Use the original screws or
new self-tapping screws.
Other special equipment: 1159795
Specifications:
110 10 Nm

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Range Gear, Overhaul PDF

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IMPACT 3.

0 Thursday, 20 September 2012

Publishing Date Operation No.

43175-5 Range gear, overhaul

Other special equipment: 1159794, 1159795

Range gear overview

Copyright Volvo Group North America

A. Engaging ring, high range

Special tools: 9996479, 9996925

Special tools: 9994078

Copyright Volvo Group North America

Remove the circlip.

Copyright Volvo Group North America

Special tools: 9988185

Remove the range gear.

Copyright Volvo Group North America

Press out the output shaft bearing.

Special tools: 9992241

If the vehicle is equipped with a retarder, perform steps 12 - 13.

Press off the retarder gear drive.

Note: For a 70 mm shaft, use 88800026.

Special tools: 9992671, 9996222, 9998542, 88800026, 88800183, 88800195

Copyright Volvo Group North America

Remove the selector fork.

Copyright Volvo Group North America

Copyright Volvo Group North America

Note: Do not wash the engaging rings.

Copyright Volvo Group North America

Remove the oil return pipe. Use wrench 9990027.

Special tools: 9990027

Remove the circlip.

Remove the washer.

Install the puller rings 88800015.

Special tools: 88800015

Copyright Volvo Group North America

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

Special tools: 9998542, 9996222

Copyright Volvo Group North America

Remove the old spacer sleeve.

Copyright Volvo Group North America

Transfer the piston rings to the new spacer sleeve.

Fit the new spacer sleeve.

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

Copyright Volvo Group North America

Press in a new high range engaging ring.

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

Fit the washer.

Fit the locking ring

Fit the oil return pipe.

Special tools: 9990027

It is important to lubricate the carbon fibre lining on synchroniser ring (C).

Copyright Volvo Group North America

Note: For a 70 mm shaft, use 88800026.

Special tools: 9992631, 9998542, 88800026

Press home a new bearing in the range housing.

Special tools: 9996788

Special tools: 9988185

Copyright Volvo Group North America

Press on the bearing in the range housing on the output shaft.

Special tools: 9996759

Copyright Volvo Group North America

Fit the pole wheel.

Other special equipment: 1159794