Volvo Trucks North America

Greensboro, NC USA

D Service Bulletin
Date

9.2008
Trucks
Group

413
No.

09

Clutch Servo, Overhaul

AT2512C, ATO2512C, AT2812C,
ATO3112C
Page

1(9)

Clutch Servo, Overhaul

T4021527

Note: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual
vehicle being serviced. However, key components addressed in this information are
represented as accurately as possible.

• “Clutch Servo, Overhaul” page 2

PV776-20165164 USA31625.ihval
Volvo Trucks North America
Service Bulletin

D
4134-04-02-01
Clutch Servo, Overhaul
Date
9.2008
Group
413
No.
09

You must read and understand the precautions and

guidelines in Service Information, group 4, "General
Safety Practices, Transmission" before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training
before you perform it.
Page
2(9)

DANGER
Do not attempt to repair or service this vehicle without
having sufficient training, the correct service literature
and the proper tools. Failure to follow this could make
the vehicle unsafe and lead to serious personal
injury or death.

1
Remove the position sensor retaining bolts and then
the sensor.

T4021478
Volvo Trucks North America
Service Bulletin

D 2
Date
9.2008
Group
413
No.
09
Page
3(9)

T4021374

DANGER
The clutch cylinder piston is under spring pressure.
Once the lock ring is removed care must be taken
to release the piston slowly, until all spring tension
is relieved. Failure to do so may result in serious
personal injury or death.

Compress the clutch cylinder piston using a vise or an

assistant. While keeping it compressed, remove the lock
ring and slowly remove the piston from the cylinder.

W4003072
Volvo Trucks North America
Service Bulletin

D
3
Date
9.2008
Group
413
No.
09

Remove the striker plate and then lift the release

bearing out.
Page
4(9)

T4021375

4
Cut and break away the plastic sleeve covering the
outer seal on the piston.

T4021376

5
Remove the inner hub seals.

Note: Note the position and direction of the seals before,

and during removal. Install all seals in the same manner.
If necessary, remove and replace the seals one at a time.

W4003073
Volvo Trucks North America
Service Bulletin

D 6
Date
9.2008
Group
413
No.
09

Remove the outer seal on the piston.

Page
5(9)

T4021377

CAUTION
Do not washed the position sensor. Washing the
sensor may cause component damage.

Clean all reused parts except the position sensor.

Examine the parts for damage. Replace any damaged
parts.
Volvo Trucks North America
Service Bulletin

D
8
Date
9.2008
Group
413
No.
09
Page
6(9)

T4021547 Install the inner hub seals as illustrated. Lubricate the

seals with the grease provided in the kit.

W4003073

9
Install the outer seal. Lubricate the seal with the grease
provided in the kit.

T4021377
Volvo Trucks North America
Service Bulletin

D 10
Date
9.2008
Group
413
No.
09

Install the new plastic sleeve over the outer seal.

Page
7(9)

Note: For easy of installation, place the sleeve on a work

bench and turn the piston over onto the sleeve. Press
down evenly on the piston. To completely seat the sleeve
use a soft surfaced hammer and tap on the piston face.

T4021376

11
Install the new release bearing and then the striker plate.

T4021378
Volvo Trucks North America
Service Bulletin

D
12
Date
9.2008
Group
413
No.
09
Page
8(9)

W4003072 Lubricate the cylinder hub with grease, position the piston
on the clutch cylinder and compress it. While keeping it
compressed, have an assistant install the lock ring.

Note: Take care not to damage the seals when seating

the piston over the cylinder hub.

T4021374
Volvo Trucks North America
Service Bulletin

D 13
Date
9.2008
Group
413
No.
09
Page
9(9)

Install the position sensor and torque the retaining bolts.

Note: Use the new retaining bolts from the kit to install
the sensor.

10±2 Nm (7±1 lb/ft)

T4021478