Bearing, Output Shaft, Replace PDF

IMPACT 3.
0 Thursday, 20 September 2012
Chassis ID Path
4/Repair/B12R, AT2412C/Bearing, output shaft, replace
Model Identity
B12R 128555499
Publishing Date Operation No.

Tuesday, 9 February 2010 43110-2
43110-2 Bearing, output shaft, replace

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.
Contents
Disassembling the gearbox

Disassembling the range gear
Assembling the range gear
Assembling the gearbox
Part number: 3092340
Special tools: 9986485, 9989876, 9990027, 9990029, 9990031, 9990084, 9992241, 9992337, 9992619, 9992671,
9994078, 9996081, 9996156, 9996222, 9996315, 9996479, 9996483, 9996788, 9996901, 9996905, 9996917,
9996925, 9998051, 9998185, 9998542, 9998570 , 9998597, 9999696, 9999737, 88800015, 88800174
Other special equipment: 1159794, 1159795, 1159796
Disassembling the gearbox

1
Remove the gearbox, see43170-1 Gearbox, remove .
2
Clean the outside of the gearbox.
Note: Plug nipples and protect valves during high pressure washing.
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 / 44
IMPACT 3.0 Thursday, 20 September 2012
Fit the intermediate flange on to the fixture plate. With the aid of the arms, fit the fixture plate to the gearbox. Secure
the gearbox into the unit stand.
Special tools: 9986485, 9990031, 9996905, 9999737
4
If the gearbox has no retarder continue with step6.

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Alternative 1

3 / 44
Alternative 2
Warning
Hot oil can cause burns. Use protective gloves.
Put an suitable vessel under the retarder's drain plug. Remove the two drain plugs (C) for retarder oil on the heat
exchanger. Also loosen the filler plug (A) and the vent plug (B) for faster draining.

4 / 44
Drain the gearbox oil off.
Remove the oil filter drain plug. Refit the drain plug after the oil has finished draining.

5 / 44
Connect the PC tool and carry out VCADS Pro Operation, 40091-3 Gearbox activation, control housing removal and
installation
To remove the control housing, the splitter gear must be in its rear position, 2nd and 3rd in neutral, and 1st/reverse in
its rear position and the range gear set to high range (the forward position).
Remove the electrical connector for the clutch valve assembly in the control housing.
10

6 / 44
Remove the screws and control housing. If necessary, carefully use a crowbar to loosen the control housing from its
guide pins.
Special tools: 9992337
11
12

7 / 44
Remove the retarder temperature sensor from the heat exchanger, or alternatively remove the connector from the
plate.
13
Alternative 1

8 / 44
Alternative 2
Remove the three screws securing the heat exchanger and retarder cooler.
14
Turn the gearbox so that the output shaft flange faces upwards.
15

9 / 44
Remove the companion flange nut and O-ring.
16

10 / 44
Pull off the companion flange.
Special tools: 9990084, 9992619, 9992671, 9996156, 9996222, 9998597
17
18

11 / 44
Remove the four nuts securing the retarder to the range housing (A, B, C and D in the illustration).
19
Carefully lift the retarder away from the gearbox.
20
Fit the adapter and lifting eye into the output shaft.
Special tools: 9996479, 9996925
21

12 / 44
Remove the plug, spring and blocking body for the range function. If necessary use a magnet to pull out the blocking
body.
22
Remove the range housing securing screws.
Note: If the gearbox has a retarder, do not forget to remove the bolts in the retarder mounting.
23

13 / 44
Press the basic housing and range housing apart. Use a press tool.
24
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.
25
Remove the oil distributor pipe. Use a socket.
26
Remove the circlip securing the high range synchronizer.

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27
Remove both halves of the washer.
28
Fit both the puller halves on to the high range synchronizer hub.
29
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, 9992619, 9992671, 9996889, 9998542

15 / 44
30
Fit the other half of the puller 9998542. Fit the hydraulic pump. Press off the high range synchronizer.
31
Lock the gears with the holder for the clutch sleeves.
32
When measuring the mainshaft and countershaft, 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 itsrearmost position.
33
Turn the gearbox 1/2 turn.
Remove the countershaft brake, see43132-5 Brake, intermediate shaft, overhaul
34

16 / 44
Turn the gearbox back 1/2 turn.

Fit screw 9996917 on the main shaft and screw 9996483 on the countershaft.
Special tools: 9996917, 9996483
35
Rotate the shaft 20 turns.
36

17 / 44
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
37
Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off any play at the marked
position.
38
Turn the gearbox back 1/2 turn
Remove the dial indicator and rotate the shaft 20 turns.
39
Fit the dial indicator to the magnetic stand. The tip of the dial indicator is to be in contact with special tool 9996483.
Zero the dial indicator and mark up the measuring point.
Special tools: 9989876, 9999696, 9996483
40
Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off any play at the marked
position.

18 / 44
41
Note: If axial play has been measured, adjust the main shaft and countershaft, to achieve the correct
preloading.
If there is axial play adjust the main shaft and countershaft, see43185-5 Main shaft and countershaft, adjust .
If no axial play is measured, it is assumed that the shafts are correctly preloaded.
42
Remove the dial indicator.
43
Fit the countershaft brake, see43132-5 Brake, intermediate shaft, overhaul .
Specifications:
45 5 Nm
Disassembling the range gear

44
Remove the lifting eye and adapter.
Special tools: 9996479, 9996925
45

19 / 44
Remove the seal ring from the housing.
46

20 / 44
Remove the toothed wheel for the speedometer. Remove the vehicle speed sensor.
47
Remove the lock ring retaining the output shaft bearing in the range housing.
21 / 44
48
Remove the bolts retaining the range gear in the housing.
49
Remove the range gear.
50
22 / 44
Press the planetary gear out of the housing.
Note: Ensure that the planetary gear runs freely and that it is not dropped and damaged.
51
Remove the planetary gear and range housing from the press.
52
Press out the output shaft bearing.

23 / 44
Assembling the range gear

53
Clean the range housing.
54
Press a new bearing home into the range housing.
55

24 / 44
Fit the thickest possible lock ring for the bearing. The maximum permitted clearance (A) is 0.1 mm.
Use a feeler gauge to measure the clearance.
Specifications:
Max. 0.1 mm
56

25 / 44
Press the range housing onto the planetary gear and output shaft.
Special tools: 9996759, 9996924
57
Install the toothed wheel for the speedometer sensor. Install the vehicle speed sensor with an undamaged gasket.
26 / 44
Torque tighten the vehicle speed sensor.
Other special equipment: 1159794
Specifications:
25 5 Nm
58
Half fill the space between the seal lips with grease.
Note: Do not grease the axial surface of the sealing ring.
59
Shaft 70 mm diameter
Put the seal onto the mandrel and drive it into the range housing. For a 70mm shaft, use 9998575.
Specifications:
70 mm
60

27 / 44
Shaft 80 mm diameter
For a 80mm shaft, use 88800174. The ring that is part of tool 88800174, shall only be used on VT boxes.
Specifications:
80 mm
61

28 / 44
Fit the range unit in the range housing and torque tighten the bolts.
Note: Tighten the bolts diagonally.
Specifications:
110 10 Nm
Assembling the gearbox

62

29 / 44
Press in the synchronizer for high range.
Special tools: 88800015, 9992671, 9996222, 9996315, 9998542
63
Fit both the washer halves.
64
Fit the high range circlip.

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65
Remove the forks (9990029) holding the clutch sleeves in place. Remove the screws (9996917 and 9996483) from the
shafts.
Special tools: 9990029, 9996483, 9996917
66
Oil and fit new O-rings. Install the oil distribution piping. Torque tighten the oil distribution piping. Use a socket.
Specifications:
250 35 Nm
67

31 / 44
Apply a string of sealant, part number 3092340 to the basic housing face, as illustrated.
Part number: 3092340
68
Fit 9996479 and 9996925 onto the range unit output shaft. Position the range housing over the gearbox housing.
Lower and line up the piston rod and planet wheel. Torque tighten the range housing bolts.
Special tools: 9996479, 9996925
Specifications:
110 10 Nm

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69
Turn the gearbox 1/4 turn, so that the control housing can be fitted from above.
70
Position a new control housing gasket.
71
Insert the dowels into the gearbox housing.
72
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 rearmost position and the range gear is set to high range (with the range shaft in its front
most position and the piston in the range cylinder in its innermost position) and that the selector forks in the control
33 / 44
housing are matched to the clutch rings.

This is to enable the control housing to be fitted.
73
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.
74
Remove the guide pins.
75
Install the control housing screws. Torque tighten the bolts diagonally.
Specifications:
110 10 Nm
76
Fit the key, spring and plug for the range.
77
Carry out the following VCADS Pro operations using the PC tool.
40105-4 Gearbox, calibration (gearbox removed)

43116-4 Gears, test (gearbox removed)
78
79
34 / 44
Turn the gearbox 1/4 turn, so that the retarder can be fitted from above.
80
Fit the retarder with a new O-ring, grease it with silicon grease. Guide the screws into their holes, and push in the
retarder until it bottoms into position. Fit the nuts and tighten them by hand as illustrated, in the order A, B, C and D.
Note: After the retarder has been tightened, there should be a gap between the retarder and the range housing. Torque
tighten the nuts in order A,B,C, and D and then 1st and 2nd angle tightening.
Specifications:
30 Nm
455
455
81
Replace the V-ring on the companion flange; the V-ring shall lie against the stop on the companion flange.
Note: Check the flange's mating surfaces to ensure that there is no visible damage.
82

35 / 44
Press the companion flange onto the shaft.
Note: The companion flange must not, under any circumstances, be heated up or hit with a hammer. The companion
flange shall be fitted and pressed home on the output shaft using the special tool provided. It is very important that the
flange is pressed completely home before the nut is tightened. If the flange is not pressed completely home, damage
can be caused to the output shaft bearing or the range oil pipe.
Special tools: 9992671, 9996222, 9996315, 9996901, 9996925
83
Fit the counterhold on the companion flange. Fit a new O-ring and nut, and torque tighten.

36 / 44
Specifications:
/
400 +150 50 Nm
84
Lock the flange nut in both recesses on the flange using a mandrel.
Note: The punch must have a rounded tip and the tabs should be driven in until they bottom. Check that no cracks
have occurred.
85
Turn the gearbox back 1/4 turn.
86
87

37 / 44
Fit new O-rings on the heat exchanger and range housing, grease them with silicon grease.
Lift the heat exchanger so that the narrow sleeves go into their holes.
88

38 / 44

39 / 44
Fit the securing bolts. Pull the heat exchanger into place using the upper rear bolts, and tighten them to the specified
torque.
Specifications:
85 Nm
89
Fit the temperature sensor for the retarder.
90

40 / 44
Remove the oil filter cover and guide sleeve.
Note: There will be a little oil left in the cover.
91
Fit a new gearbox filter.
Specifications:
505 Nm
92
Fit the gearbox, see43172-1 Gearbox, install
93
94

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Alternative 1

42 / 44
Alternative 2
Tighten the two oil drain plugs (C) to 16 Nm for alternative 1 and 13 Nm for alternative 2.
Fill the retarder with oil.
Oil volume, litre
Retarder Production Service Heat exchanger

filling filling completely
drained from
oil
RET-TH 6,1 5,4 6,1
For oil grade, seePreventive maintenance intervals .
Specifications:
16 Nm
13 Nm
95
Fit the ventilation plug (B) and tighten it to 13 Nm.
Specifications:
13 Nm
96
Fill the coolant system, see. function group 26.
43 / 44
97
Fill the gearbox with oil.

44 / 44

Bearing, Output Shaft, Replace PDF

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IMPACT 3.

0 Thursday, 20 September 2012

Publishing Date Operation No.

43110-2 Bearing, output shaft, replace

Disassembling the gearbox

Part number: 3092340

Other special equipment: 1159794, 1159795, 1159796

Disassembling the gearbox

Copyright Volvo Group North America

Special tools: 9986485, 9990031, 9996905, 9999737

Copyright Volvo Group North America

Copyright Volvo Group North America

Copyright Volvo Group North America

Drain the gearbox oil off.

Copyright Volvo Group North America

Copyright Volvo Group North America

Special tools: 9992337

Copyright Volvo Group North America

Copyright Volvo Group North America

Copyright Volvo Group North America

Remove the companion flange nut and O-ring.

Special tools: 9998570

Copyright Volvo Group North America

Pull off the companion flange.

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

Copyright Volvo Group North America

Special tools: 9996479, 9996925

Copyright Volvo Group North America

Remove the range housing securing screws.

Copyright Volvo Group North America

Special tools: 9998051

Remove the oil distributor pipe. Use a socket.

Special tools: 9990027

Remove the circlip securing the high range synchronizer.

Remove both halves of the washer.

Special tools: 88800015

Special tools: 88800015, 9992619, 9992671, 9996889, 9998542

Special tools: 9996222

Special tools: 9990029

Copyright Volvo Group North America

Turn the gearbox back 1/2 turn.

Special tools: 9996917, 9996483

Rotate the shaft 20 turns.

Copyright Volvo Group North America

Special tools: 9989876, 9999696

Special tools: 9989876, 9999696, 9996483

Copyright Volvo Group North America

Disassembling the range gear

Remove the lifting eye and adapter.

Special tools: 9996479, 9996925

Copyright Volvo Group North America

Remove the seal ring from the housing.

Special tools: 9994078

Copyright Volvo Group North America

Special tools: 9988185

Remove the bolts retaining the range gear in the housing.

Remove the range gear.

Press the planetary gear out of the housing.

Press out the output shaft bearing.

Special tools: 9992241

Copyright Volvo Group North America

Assembling the range gear

Press a new bearing home into the range housing.