05:01-04

Issue 1 en

Gearbox

GRS890
GRS900
GRS920
GRSH900
GRSO900

Shafts

Work Description

©Scania CV AB 2005, Sweden

1 714 660
Contents

Contents
Input shaft Exploded view drawings .......................................... 3
Dismantling .............................................................. 4
Assembly .................................................................. 7

Mainshaft Exploded view drawing .......................................... 10

Dismantling ............................................................ 12
Renewing bearing races for splitter gearwheel....... 15
Assembly ................................................................ 17

Layshaft Exploded view drawing .......................................... 24

Dismantling ............................................................ 25
Assembly ................................................................ 29

Specifications Materials ................................................................. 33

Tightening torques .................................................. 33

©Scania CV AB 2005, Sweden

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 Input shaft

Input shaft

Exploded view drawings

GRS890, GRS/GRSH900
2
7
8
7
6 1 Shaft
2 Snap ring
3 Bearing
4
4 Gear
5
5 Needle bearing
3
6 Sealing ring
7 Piston ring
8 Spacing ring
9 Pipe

1
136 218

GRS920, GRSO900
2
7
6 1 Shaft
2 Snap ring
3 Bearing
4 4 Gear
5 5 Needle bearing
3 6 Sealing ring
7 Piston ring
8 Pipe

1
136 219

©Scania CV AB 2005, Sweden

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Input shaft

Dismantling

Special tools

Number Description Illustration Tool board

87 596 Slide hammer 87 596 D2

00 1610
99 136 Hollow drift 99 136
P1

00 1622
99 141 Support ring 99 141
P1

00 1623

Other tools

Number Description Illustration

587 312 Snap ring pliers 587 312
111 445

©Scania CV AB 2005, Sweden

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 Input shaft

1 Remove the two piston rings by hand.

Earlier gearboxes may have a spacing ring
between the piston rings.

2 Remove the snap ring. Use snap ring pliers

587 312. It may be necessary to tap the
bearing inner race with something first, such
as a drift and hammer.

3 Place the shaft on hollow drift 99 136 and

support ring 99 141. Press out the bearing
and gear. Place something soft underneath
to protect the shaft when it comes loose.

©Scania CV AB 2005, Sweden

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Input shaft

4 Remove the bearing and the gear. Remove

the bearing shells.
If the input shaft is the old type, i.e. with the
oil pipe pressed into the input shaft, remove
as follows.

5 Tap the oil pipe using an M10 pilot tap.

6 Pull out the oil pipe using an M10 bolt with

welded-on washer and slide hammer
87 596. Clean the oilway.

©Scania CV AB 2005, Sweden

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 Input shaft

Assembly

Special tools

Number Description Illustration Tool board

98 224 Pressplate 98 224
G1

110 065
98 334 Counterholding tube 98 334
G3

110 120
98 450 Shank R2, AD2, AM1
00 1633

98 450

98 636 Assembly drift 98 636

G1
110 815

99 136 Hollow drift 99 136

P1
00 1622

99 141 Support ring 99 141

P1
00 1623

Other tools

Number Description Illustration

587 312 Snap ring pliers 587 312
111 445

©Scania CV AB 2005, Sweden

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Input shaft

If the input shaft is the old type, i.e. with the oil
pipe pressed into the shaft, fit as described in
steps 1-2.
1 Place the shaft in pressplate 98 224.

2 Press in the oil pipe using shank 98 450.

Press in the pipe so that it protrudes at least
21.5 mm (dimension A). Check that the
lubricating holes are clear. The pipe must
not be upset.

3 Fit the bearing shells and the gear with the

splines downwards.

4 Press on the bearing using counterholding

tube 98 334 and assembly drift 98 636.

©Scania CV AB 2005, Sweden

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 Input shaft

5 Fit the snap ring using snap ring pliers

587 312. Select a snap ring which provides
the least possible clearance between the ring
and bearing. Check that the snap ring goes
down into the groove.

6 Place the shaft on hollow drift 99 136 and

support ring 99 141. Press the bearing
against the snap ring using a press force of
70 kN max. (7 tonnes).

7 Fit the two piston rings. Earlier versions

also have a spacing ring between the piston
rings.

©Scania CV AB 2005, Sweden

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Mainshaft

Mainshaft

Exploded view drawing

©Scania CV AB 2005, Sweden

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 Mainshaft

1 Mainshaft 29 Cone
2 Bearing 30 Driver
3 Nut 31 Compression spring
4 Roller bearing 32 Plunger
5 Spacing ring 33 Clevis pin
6 Shim 34 Shift sleeve
7 Gear 35 Latch cone
8 Gear 36 Cone
9 Needle bearing 37 Synchromesh cone
10 Gear 38 Driver
11 Snap ring 39 Compression spring
12 Needle bearing 40 Plunger
13 Gear 41 Clevis pin
14 Slide bearing 42 Shift sleeve
15 Driver 43 Latch cone
16 Coupling sleeve 44 Coupling disc
17 Gear 45 Spring pin
18 Slide bearing 46 Snap ring
19 Slide bearing 47 Synchromesh
20 Nozzle 48 Intermediate cone
21 Shim 49 Latch cone
22 Spacing ring 50 Driver plate
23 Shift sleeve 51 Compression spring
24 Snap ring 52 Plunger
25 Sun wheel 53 Clevis pin
26 Spacing washer 54 Washer
27 Shim 55 Shift sleeve
28 Nut 56 Driver

©Scania CV AB 2005, Sweden

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Mainshaft

Dismantling
Special tools

Number Description Illustration Tool board

87 237 Support drift G2
98 322 Lifting handle 98 322
G2

109 805
98 575 Support drift 98 575
G2

00 1621
99 136 Hollow drift 99 136
00 1622
P1

99 140 Support ring 99 140

P1
111 007

99 202 Split support ring 99 201

P1
111 022

Other tools

Number Description Illustration

587 318 Puller plate
114 693

587 319 Puller

587 600 Socket D
Di

L
00 1890

©Scania CV AB 2005, Sweden

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 Mainshaft

1 Pull off the front bearing. Use support drift

87 237, puller plate 587 318 and puller
587 319.

! WARNING!

Wear protective goggles. There is a risk

of flying fragments if the bearing breaks.

2 Remove the round nut, use socket 587 600.

3 Fit lifting handle 98 322 and lift the shaft

onto the press.

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Mainshaft

4 Lower the shaft into hollow drift 99 136.

When the shift sleeve is down in the hollow
drift, fit the split support ring 99 202. Centre 98 575
carefully. Place, for example, a rubber cloth
in the drift to cushion the fall.

5 Press out the rear bearing, reverse shaft gear,

crawl and first gears. Protect the ends of the
shaft using support drift 98 575. Remove the
bearing, gears and synchromesh assembly. 99 202
Keep the synchromesh assembly as a unit.
Mark the parts and place the assembly to 99 136
one side.

133 794
6 Turn the shaft and place it in hollow drift
99 136. Use support ring 99 140. Protect the
ends of the shaft using support drift 98 575.

7 Press out the shaft. Remove the second gear

and splitter gear with their corresponding
synchromesh assembly. Mark the splitter
gearwheel so that it faces in the same
direction during assembly. Keep the
synchromesh assembly as a unit. Mark the
parts and place the assembly to one side.

©Scania CV AB 2005, Sweden

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 Mainshaft

Renewing bearing races for splitter gearwheel

Special tools

Number Description Illustration Tool board

87 446 Drift 87 446
AD2

00 1581
87 758 Drift 87 758
G1

00 1611

Other tools

Number Description Illustration

587 316 Counterhold
114 058

587 530 Puller

115 110

©Scania CV AB 2005, Sweden

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Mainshaft

1 Mount the gearwheel in a vice with soft

jaws. Use puller 587 530 and counterhold
587 316 to pull out one bearing race. Use a
separator plate made of e.g. aluminium
sheet.

2 Press out the other bearing race using drift

87 758.

3 Press in new bearing races using drift

87 446.

©Scania CV AB 2005, Sweden

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 Mainshaft

Assembly

Special tools

Number Description Illustration Tool board

87 089 Drift 87 089

AM2, D3

110 283
87 550 Drift 87 550

AD2

00 1628
87 932 Drift 87 932
D3, G1
00 1636

88 292 Pull rod 88 292

00 1848

G2

98 075 Dial gauge 98 075

D2
0
90 10
10 90

80 20
20
80

15 5
30 10
70
70 30

40 60
60 50 40
50
00_1637

98 568 Drift 98 568

AM1
00_1618

98 575 Support drift 98 575

G2
00 1621

99 127 Drift 99 127 AM1

00 1629

99 136 Hollow drift 99 136

P1
00 1622

©Scania CV AB 2005, Sweden

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Mainshaft

Number Description Illustration Tool board

99 140 Support ring 99 140
P1

111 007
99 190 Drift 99 190
G4

00 1638
99 191 Drift 99 191
G4

109 785
99 199

99 199 Counterhold G4

111 021

Other tools

Number Description Illustration

587 250 Indicator stand with magnetic
base
102350

587 600 Socket D

Di

L
00 1890

1 Fit the needle bearing.

2 Fit the second gear with the spline flange
upwards.

©Scania CV AB 2005, Sweden

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 Mainshaft

3 Fit the synchromesh assembly for second

and third gears with the longer neck of the
driver downwards. Guide onto the splines
and press if necessary.

05_3289
4 Press one bearing onto the splitter
gearwheel, use drifts 99 190 and 99 191.

5 Fit the spacing ring first and then the shims.

When measuring the clearance, you should
start with too much clearance. Therefore fit
one shim more than before.

6 Fit the splitter gearwheel. Fit it onto the

splines on the synchromesh cone.

©Scania CV AB 2005, Sweden

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Mainshaft

7 Press on the other bearing using drift 99 190

and 99 191. Rotate the gear while pressing.
Stop pressing if it is hard to rotate the wheel
and change to a thicker shim. See step 11.

8 Fit the round nut. Use counterhold 99 199,

pull rod 88 292 and socket 587 600.
Tightening torque 400 Nm.

9 Check the splitter gearwheel clearance.

Leave the shaft on counterhold 99 199, or
clamp the shaft in a press with 10 - 20 kN.
Fit dial gauge 98 075 and indicator stand
587 250.

10 Rotate the gear a few turns, always in the

same direction. Prise the gear upwards using
two screwdrivers. Rotate the gear and
perform at least three measurements, mark
the gear so that the measurements are
carried out at the same position. Take the
average. Correct clearance: 0.03 - 0.09 mm.

©Scania CV AB 2005, Sweden

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 Mainshaft

11 Adjusting the clearance: Press up the shift

sleeve to gear position 3. Place the shaft in
hollow drift 99 136 with support rings
99 140 and press out the bearing using drift
98 575. Fit new shims and begin again from
step 6.

12 Lock the nut on the two recesses provided

for the purpose and remove counterhold
99 199.

122 564

13 Turn the mainshaft over. Use drift 98 568 as

a support under the shaft if the front bearing
is pressed on.

14 Lubricate and fit the needle bearing.

©Scania CV AB 2005, Sweden

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Mainshaft

15 Line up the synchromesh assembly and

place it in position on the first gear. Then fit
the gear with the synchromesh assembly on
the shaft.

16 Lubricate and press on the inner ring for the

crawl gear needle bearing. Use drifts 87 550
and 99 127. Fit the needle bearing.

17 Fit the crawl gear with the coupling teeth

upwards. Fit the driver, press if necessary.
Use drifts 87 550 and 99 127.

18 Fit the shift sleeve.

©Scania CV AB 2005, Sweden

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 Mainshaft

19 Lubricate and press on the inner ring for the

reverse gear needle bearing. Use drifts
87 932 and 99 127.

20 Fit the reverse gear needle bearing and the

gear with the coupling teeth downwards.

21 Lubricate the rear bearing and press it on

using drift 87 932.

22 Turn the shaft and press on the front

bearing, use drift 87 089.

©Scania CV AB 2005, Sweden

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Layshaft

Layshaft

Exploded view drawing

All versions of GRS gearboxes have a layshaft
which is designed in the same way, what differs
is, for example, the number of teeth and the
strength of the gearwheels.

1 Shaft
2 Retaining ring
3 Bearing
4 Gear
5 Gear
6 Spacing sleeve
7 Gear
8 Bearing
9 O-ring
10 Shim
11 Retaining ring

©Scania CV AB 2005, Sweden

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 Layshaft

Dismantling

Special tools

Number Description Illustration Tool board

98 575 Support drift 98 575
G2

00 1621
98 647 Support drift G2
99 136 Hollow drift 99 136
P1

00 1622

99 140 Support ring 99 140

P1
111 007

99 142 Support ring 99 142 P1

00 1624

99 143 Split support ring 99 143

P1
111 008

99 450 Split support ring PT1

128 352

©Scania CV AB 2005, Sweden

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Layshaft

Other tools

Number Description Illustration

587 312 Snap ring pliers 587 312

111 445
587 318 Puller plate

114 693
587 319 Puller

1 Pull off the rear bearing using puller plate

587 318 and puller 587 319. Use support
drift 98 647. If the bearing breaks, split it.

! WARNING!

Wear protective goggles.

2 Pull off the front bearing using puller plate

587 318 and puller 587 319. Use support
drift 98 647. Loosen the bearing slightly
first, then grasp it again. If the bearing
breaks, split it.

©Scania CV AB 2005, Sweden

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 Layshaft

3 Remove the snap ring. Use snap ring pliers

587 312.

4 Place the layshaft in a press. Centre

carefully.
GRSO900: Press off the layshaft high split
gearwheel. Use hollow drift 99 136 with
split support ring 99 450 and support drift
98 575.
OTHERS: Press off the layshaft low split
gearwheel. Use hollow drift 99 136 with
split support ring 99 143 and support drift
98 575.
GRSO900
Place, for example, a rubber cloth in the
hollow drift to cushion the fall of the shaft
when it drops down.

Other gearboxes

5 Press off the next splitter gearwheel. Use

hollow drift 99 136 with support ring
99 140. Remove the spacing ring.

©Scania CV AB 2005, Sweden

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Layshaft

6 Press out the second gear. Use hollow drift

99 136, support ring 99 142 and support
drift 98 575.

©Scania CV AB 2005, Sweden

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 Layshaft

Assembly

Special tools

Number Description Illustration Tool board

98 575 Support drift 98 575
G2

00 1621
98 638 Assembly drift 98 638
G3

110 816
99 136 Hollow drift 99 136
P1
00 1622

99 142 Support ring 99 142

P1
00 1624

99 190 Drift 99 190

G4
00 1638

99 191 Drift 99 191

G4
109 785

99 450 Split support ring PT1

128 352

Other tools

Number Description Illustration

587 312 Snap ring pliers 587 312
111 445

©Scania CV AB 2005, Sweden

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Layshaft

All gears are bonded onto the layshaft. Before

the gears are bonded onto the shaft, the surfaces
must be carefully cleaned with degreasing
solvent. Then use locking compound 584 075
(Loctite 16 705) which is spread evenly over
both surfaces for good adhesion.

IMPORTANT! To guarantee the strength of the

locked joint, the press force when fitting must
reach at least 300 kN (30 tonnes) just before the
gears reach the bottom. If the force is not
attained, the shaft and/or gear should be
scrapped. The reason for this is that if you do
not use the correct locking compound and attain
the correct press force, the gears will rotate on
the shaft.

1 Place the second gear on support ring

99 142 and press in the shaft.

Note: Protect the ends of the shaft using support

drift 98 575. The press force must reach at least
300 kN (30 tonnes) before the gear reaches the
bottom.

©Scania CV AB 2005, Sweden

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 Layshaft

2 Place the high split gear (low split gear for

GRSO900) on support ring 99 142. Fit the
spacing ring on the shaft and press on the
gear.

Note: Protect the ends of the shaft using support

drift 98 575. The press force must reach at least
300 kN (30 tonnes) before the gear reaches the
bottom.

3 GRSO900: Place the high split gear on

support ring 99 450 and press in the shaft.
OTHERS: Place the low split gear on
support ring 99 142 and press in the shaft.

Note: Protect the ends of the shaft using support

drift 98 575. The press force must reach at least
300 kN (30 tonnes) before the gear reaches the 99 450
bottom.

GRSO900 Other gearboxes

4 Press on the rear bearing. Use drift 99 190

and drift 99 191.

©Scania CV AB 2005, Sweden

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Layshaft

5 Turn the shaft in the press. Fit the snap ring.

6 Place the shaft on drift 99 191. Press on the

front bearing. Use assembly drift 98 638.

©Scania CV AB 2005, Sweden

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 Specifications

Specifications

Materials
Sealing agent part No. 584 010
Locking compound 561 200

Tightening torques
Round nut on mainshaft 400 Nm + locking
compound
Lock bolt for reverse gear shaft 50 Nm + locking
compound
Pressure relief valve 45 Nm
Oil pipe 26 Nm
Oil nozzle in shaft 80 Nm
Oil pump bolts 10 Nm
Clutch housing retaining bolts 210 Nm
Support sleeve retaining bolts 26 Nm
Round nut, end yoke 600 Nm
Drain and level plugs 100 Nm

©Scania CV AB 2005, Sweden

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 ©Scania CV AB 2005, Sweden
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 ©Scania CV AB 2005, Sweden
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 ©Scania CV AB 2005, Sweden
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