Range Gear, Overhaul

IMPACT 3.
0 Monday, 6 May 2013
Chassis ID Path
43/Repair/FM9, VT2009B, RET-TH/Range gear, overhaul. Unit removed
Model Identity
FM9 121615501
Publish date Operation No.

Wednesday, 17 December 2008 43175-5
43175-5 Range gear, overhaul

Unit removed
Special tools: 9990069, 9990070, 9990071, 9990072, 9991187, 9992000, 9992619, 9992653, 9992671, 9994078,
9996041, 9996205, 9996222, 9996225, 9996239, 9996315, 9996499, 9996518, 9996541, 9996600, 9996603,
9996673, 9996674, 9996686, 9996737, 9996760, 9996897, 9996901, 9996904, 9996925, 9996927, 9998351,
9998570, 9998575, 9998597, 9999335
Other special equipment: 1159794, 1159796, 9988185
Disassembly
Remove the three screws which secure the heat exchanger to the range housing.
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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 / 24
IMPACT 3.0 Monday, 6 May 2013
Remove the nuts which hold the retarder.
3
Turn the companion flange so that one of the bevellings is against the retarder.
Carefully lift the retarder off.
Special tools: 9996239

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Remove the cover on the range cylinder.
Remove the companion flange nut and O ring. Use the counterhold.

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Pull off the companion flange.
Special tools: 9996222 9998597 9992671 9992619 9992653
8
Remove the emergency steering servo pump, if fitted.
9
Remove the vehicle speed sensor.
10
Remove the screw which retains the piston in the range cylinder's piston rod
11

4 / 24
Remove the range cylinder.
Note: It can be difficult to move. Be careful with the O ring between the piston and the piston rod.
12
Press the range gear out of the housing.
Note: Make sure that the piston rod moves freely and that the range gear does not fall onto the floor or the press table
and get damaged.
13
Remove the housing, selector fork and planet wheel from the press.
14

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Remove the seal ring from the housing.
15
Remove the cover from the power take-off.
16

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Remove the toothed wheel for the speedometer.
17
Remove the circlip from the bearing.
Other special equipment: 9988185
18

7 / 24
Press the bearing out.
19
Pull off the cog wheel which drives the retarder.
Special tools: 9996518 9996541 9996499 9999335 9990072 9990069
20

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Remove the intermediate disc.
21
Remove the spacer sleeve, engaging ring and synchronising crown from the low range and ring gear.
22
Remove the circlip in the ring gear, the release sleeve, the synchronising crown and the spring ring.
23
Press in the spring ring and remove the high range engaging ring.
Note: The planet wheel holder and the axle are balanced after factory assembly and for this reason must not be
pushed apart.
24
Clean and check all components.
25
Check the wear surfaces of engaging rings and synchronising rings. Rings with completely or partly worn grooves and
blued surfaces must be changed. Synchronising rings which are blued from the inside, all the way to the outside, must
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be changed.
26
Put the components on a table, so that they partly overlap the edge of the table. Make sure that the synchronising cone
lies flat on the engaging ring, and measure from the underside of the engaging ring to the top of the synchronising ring.
Measure at several places.
Synchronisation New Min. [mm]

components
[mm]
High range 32,7±0.3 31,6
27
Check that the planet wheel easily rotates and that the planet wheel's axial clearance lies between 0,6-1,3 mm. Also
check the surfaces of the cogs.
Note: In the event of a wheel having to be changed, all wheels, pins, needle bearings and washers must be changed.
Specifications:
0,6-1,3 mm
28

10 / 24
Put the planet wheel holder in the press, press out the shaft stubs.
Special tools: 9992000 9996205
29
Remove the gear wheels, washers and rollers. Check that there are no burrs in the pin holes.
Note: If any component has to be changed, all components must be changed.
Assembly
30

11 / 24
Put the needle bearings and spacer washers in the planet wheel, the steel washers and the metal washers.
31
When putting the needle bearings in the planet wheel, use a sleeve with a diameter of 32,0-32,4 mm and length of 40
mm. This is to make assembly easier.
32
Put on the thrust washers and put the planet wheel in the planet wheel holder.
Note: The steel washers must be situated nearest to the wheel.
33
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The pins should go in the holder easily, and lie flat with the planet wheel holder.
Note: Check that the shaft stubs do not deviate from the planet wheel holder plane during pressing.
34
Fix the press tool in a vice and install the tool.
Special tools: 9991187 9996600 9996222 9996603 9996673 9996674 9996686 9996897
35

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Put the planet wheel holder in the press tool and upset the shaft. Press until 6 tons press pressure has been attained.
Specifications:
6 tons
36
Turn the riveting punch so that the next press mark comes between the previous marks. Press until 6,5 tons press
pressure has been attained.
Specifications:
6,5 tons
37
Remove tool 9996897 and put in tool 9996927. Place the mandrel so that the spindle is upset in the indentation on the
planet wheel holder. Press until 6,5 tons press pressure has been attained.

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Specifications:
6,5 tons
38
Check that the wheels turn easily and that the axial clearance lies between 0,6-1,3 mm.
Specifications:
0,6-1,3 mm
39
Oil in all bearings, sliding surfaces and O rings, with gearbox oil during assembly.
40
Put on the circlip for the engaging ring high range. Press the circlip together and install the engaging ring.
41
In order to be sure that the correct locking force is attained in the synchronisation, the spring on the inside of the
release sleeve should be changed for a new one. Put on the synchronising cone for high range, the ring gear, the
release sleeve, the circlip and the synchronising cone for low range.
42

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Put on the intermediate disc.
43
Press on the gear for the retarder drive.
44

16 / 24
Press the bearing in until it bottoms.
45
Install the thickest possible bearing circlip. Max acceptable clearance: 0,1 mm.
Specifications:
0,1 mm
46
Carefully place the range gear on the mandrel 9990070 and 9996760 on the edge of a table.
47

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Put on the selector fork.
Note: The selector fork with piston rod should be put in the large recess of the intermediate disc in order that the
intermediate disc shall be in the right position during assembly. If the screws have been loose or have been removed,
the top screw must be tightened first. Torque by 75 ± 5 Nm. Lock the screws with centre punch.

Specifications:
75 ± 5 Nm
48

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Carefully lower the range housing.
Note: Make sure the cogs on the intermediate disc fit correctly into the range housing.
49
Carefully push in the range gear and at the same time check from below and through the hole for the power take-off
that the intermediate disc has been put in the right place in the housing, without being at an angle which would damage
the teeth in the range housing.
Special tools: 9992671 9996315 9996222 9996901 9996225
50
Install the toothed wheel for the speedometer.
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51
Fill the space between the sealing lips with grease 1161963.
1161963
52
Put the seal ring on the drift and drive it in.
53
Press the flange on.
Special tools: 9992671 9996222 9996901 9996925 9996041

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54
Install a new O ring.
55
Note the cutouts in the flange, to lock the nut. Oil in threads and nut plane. Fit a new companion flange nut and torque
by 400 +150 /–50 Nm. Use tool 9998570 as a counterhold on the flange. Lock the companion flange nut in both grooves
(A) on the companion flange nut with a mandrel. The mandrel must have a rounded tip and should be pushed in right to
the bottom.
Note: Check that no cracks have formed.

Specifications:
400 +150 /–50 Nm
56
Half fill the space between the lips of the piston rod seals with grease 1161963, also grease the cylinder.
1161963
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57
Install the range cylinder.
Note: If necessary, the O ring should be changed for a new one.
58
Grease the piston seal grooves. Install the seals and support straps on the piston. Grease in the piston and seals with
1161963. Put the O ring on the piston rod.

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1161963
59
In order to avoid damaging the seals during assembly, use the piston ring compressor. Use the longest screw as a
guide when inserting the piston in the cylinder, to ensure that the piston rod O ring does not fall down into the cylinder.
Put the cleaned screw into the piston, screw it into the piston rod.
Note: Check that the countersink on the piston faces the piston rod. Then slide the piston in towards the piston rod.
Remove the screw which is used as a guide.
60
Put on a new screw which retains the piston. Torque by 40 ± 5 Nm.

Specifications:
40 ± 5 Nm
61
Fit the cover. Torque the screws crosswise by 40 ± 5 Nm.

Specifications:
40 ± 5 Nm
62
Fit the cover for the power take-off and possibly a new gasket and O ring. Torque the screws by 40 ± 5 Nm.

Specifications:
40 ± 5 Nm
63
Put on the speed sensor. Torque the screws by 25 ± 5 Nm.

Specifications:
25 ± 5 Nm
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64
Put on the new O rings, greased with silicon-free grease for the retarder.
65
Lift on the retarder, push the retarder in so that the bolts guide it in.
Note: Turn the companion flange so that one of the bevels is against the retarder housing.
66
Put the nuts on and tighten them by hand as in the picture, in the order: A, B, C, D. Pull in the retarder.
67
Tighten the nuts by 30 Nm in the correct order and after that angular torque in that order 45 ± 5°, angular torque, and
after that a further 45 ± 5° in the correct order.

Specifications:
30 Nm 45 ± 5° 45 ± 5°
68
Put new O rings on the necks and on the range housing, grease them in with silicon-free grease.
69
Put on the heat exchanger so that the slender necks are guided into their holes, put on the screws. Pull the heat
exchanger in with the upper rear screw. Torque the screws by 80 Nm.

Specifications:
80 Nm

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Range Gear, Overhaul

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IMPACT 3.

0 Monday, 6 May 2013

Publish date Operation No.

43175-5 Range gear, overhaul

Other special equipment: 1159794, 1159796, 9988185

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the nuts which hold the retarder.

Carefully lift the retarder off.

Special tools: 9996239

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the cover on the range cylinder.

Special tools: 9998570

COPYRIGHT © Copyright Volvo Parts Corporation

Pull off the companion flange.

Special tools: 9996222 9998597 9992671 9992619 9992653

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the range cylinder.

Press the range gear out of the housing.

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the seal ring from the housing.

Special tools: 9994078

Remove the cover from the power take-off.

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the toothed wheel for the speedometer.

Remove the circlip from the bearing.

Other special equipment: 9988185

COPYRIGHT © Copyright Volvo Parts Corporation

Press the bearing out.

Special tools: 9996904

Pull off the cog wheel which drives the retarder.

Special tools: 9996518 9996541 9996499 9999335 9990072 9990069

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the intermediate disc.

Synchronisation New Min. [mm]

High range 32,7±0.3 31,6

COPYRIGHT © Copyright Volvo Parts Corporation

Special tools: 9992000 9996205

Note: If any component has to be changed, all components must be changed.

COPYRIGHT © Copyright Volvo Parts Corporation

Note: The steel washers must be situated nearest to the wheel.

Fix the press tool in a vice and install the tool.

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

Special tools: 9996927

COPYRIGHT © Copyright Volvo Parts Corporation

Put on the intermediate disc.

Press on the gear for the retarder drive.

Special tools: 9990070 9990071

COPYRIGHT © Copyright Volvo Parts Corporation

Press the bearing in until it bottoms.

Special tools: 9996737

Special tools: 9990070 9996760

COPYRIGHT © Copyright Volvo Parts Corporation

Put on the selector fork.

Other special equipment: 1159794

COPYRIGHT © Copyright Volvo Parts Corporation

Carefully lower the range housing.

Special tools: 9992671 9996315 9996222 9996901 9996225

Put the seal ring on the drift and drive it in.

Special tools: 9998575

Press the flange on.

Special tools: 9992671 9996222 9996901 9996925 9996041

Install a new O ring.

Note: Check that no cracks have formed.