Boite Volvo

IMPACT 3.
0 Friday, 2 July 2010
Chassis ID

Path
431/Repair/B12B, AT2412C/Gearbox,
disassemble-inspect-assemble. Gearbox removed
Model
B12B
Identity
129315261
Publish date
Saturday, 22 May 2010
Operation No.
43187-4
43187-4 Gearbox, disassemble-inspect-assemble

Gearbox removed
Illustrations are used for several different variants: some details may therefore differ from the variant you are working
on. The essential information in the illustrations is however always correct.
Warning
Always it has necessity to use compressed air in some place of the gearbox, must wear the safety glasses.
Special tools: 9986485, 9989876, 9990027, 9990028, 9990029, 9990031, 9990120, , 9992000, 9992215, 9992337,
9992613, 9992619 , 9992671, 9996041, 9996042, 9996081, 9996176, 9996222, 9996239, 9996315, 9996479,
9996483, 9996876, 9996889, 9996905, 9996910, 9996917, 9996925, 9998051, 9998401, 9998542, 9999696,
9999737, 88800005, 88800006, 88800015, 88800033, 88800034, 88800035, 9992003
Other special equipment: 1159794, 1159795
Contents
Disassembly.
Inspection.
Assembly.
Disassembly
COPYRIGHT © Copyright Volvo Parts Corporation

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 Friday, 2 July 2010
1
Clean the outside of the gearbox.
Note: Plug nipples and valves during high pressure washing.
Connect a computer with the VCADS program installed. Use 40091-3 Gearbox activation, control housing (for
removal/fitting). In order for you to be able to remove the control housing, the splitter gear must be in its rear position,
2nd and 3rd in neutral and 1st/reverse in the rear position and set to the high range.
Go to step 14 if the VCADS program makes contact with TECU. Otherwise go to the next step.

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Note: If VCADS Pro cannot make contact with the TECU the control housing must be manually moved to the correct
position so that it can be lifted away from the gearbox.
The illustration shows the positions that the different air cylinders in the control housing must have in order for the
control housing to be lifted away.
In order for you to be able to remove the control housing, the splitter gear must be in its rear position, 2nd and 3rd in
neutral and 1st/reverse in the rear position and set to the high range.
Remove the screws holding the control housing on the gearbox. Remove the screws holding the cover on the TECU.
The figure shows the screw for the cover.

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Carefully lift the cover and disconnect the cable harness between the cover and control housing.
Fit 4 screws (see figure). Tighten the screws so as not to damage the surface of the control housing. This ensures that
the control housing cannot move and damage the pulse wheel on the main shaft.

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DD
OD
The figure shows where the various air ducts are that are used to manually operate the control housing air cylinders.

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DD

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OD
Put the splitter gear in its rear position using a compressed air nozzle. If possible engage the forward position first in
order to check that the splitter gear moves correctly.

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Put the range gear in its forward position using a compressed air nozzle. If possible engage the rear position first in
order to check that the splitter gear moves correctly.
10

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Check whether the gearbox is in neutral by turning the output shaft companion flange. If it does, blow in the hole for
reverse to engage the basic gearbox reverse gear. If not, go to the next step.
11

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If it is not possible to engage reverse gear, engage 2nd or 3rd gear.
The 2nd and 3rd gear air cylinder must be in neutral before reverse gear can be engaged. Note that there is a
mechanical engagement interlock built into the control housing that makes it impossible to engage reverse unless 2nd
or 3rd gear air cylinder is in neutral.
12

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Use a compressed air nozzle to put 2nd and 3rd gear air cylinders in neutral by carefully blowing into 2nd and 3rd gear
holes while at the same time turning the output shaft companion flange a little in order to better feel when neutral is
engaged.
13

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Use a compressed air nozzle to engage the basic gearbox reverse gear.
14
Remove the electrical connector for the clutch valve assembly in the control housing.
15

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Remove the pneumatic connection to the valve assembly, and remove the three screws securing the valve assembly.
16
Remove the electrical connection for the clutch position sensor on the valve assembly. Remove the valve assembly.
17
Fit the spacer flange onto the fixing plate. With the aid of the arm, fit the fixing plate to the gearbox. Secure the
gearbox into the unit stand.
Special tools: 9986485, 9990031, 9996905, 9999737

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18
Drain the gearbox oil.
Warning
Hot oil can cause burns. Use protective gloves.
19
Remove the oil filter drain plug. Refit the drain plug after the oil has finished draining.
20

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Remove the oil filter cover and guide sleeve.
Note: There will be a little oil left in the cover.
21
Remove the oil filter housing and where applicable the oil cooler.
22
Remove the control housing. If necessary, carefully use a crowbar to loosen the control housing from its guide pins.

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Special tools: 9992337
23
If the gearbox is equipped with a retarder, perform step 24 – 26. Otherwise go to step 27.
24
Remove the retarder's temperature sensor from the heat exchanger or alternatively, remove the connector from the
plate.
25
Remove the retarder wiring cable ties.
26

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Remove the three screws securing the heat exchanger and retarder cooler.
27
Turn the gearbox so that the output shaft flange faces upwards.
28
Fit counterhold 9998570.

Remove the companion flange nut and O-ring.
29

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Remove the companion flange.
Special tools: 9990084, 9992619, 9992671, 9996156, 9996222, 9998597
30

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Remove the plug, spring and blocking body for the range function. If necessary use a magnet to pull out the blocking
body.
31
If the gearbox is equipped with a retarder, perform step 32 – 33. Otherwise go to step 34.
32
Remove the four nuts securing the retarder to the range housing (A, B, C and D in the illustration).
33
Carefully lift the retarder away from the gearbox.
34

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Remove the range housing securing screws.
Note: If the gearbox has a retarder, do not forget to remove the screws from the retarder socket.
35
Fit the adapter and lifting eye into the output shaft.
Special tools: 9996479, 9996925
36

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Split the main housing and range housing. Use press tool.
37
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.
38
Remove the oil distributor pipe. Use a socket.
39

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Remove the circlip securing the high range synchronizer.
40
Remove both halves of the washer.
41
Fit both the puller halves on to the high range synchronizer hub.
42

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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, 9998542, 9992671, 9996889, 9998542
43
Fit the other half of the puller 9998542. Fit the hydraulic pump. Press off the high range synchronizer.
44

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Remove the reversing shaft centre screw.
45
Remove the rear cover and adjustment washer for the countershaft.
46
Fit the puller and spindle to the reversing shaft.
Special tools: 9996315, 9996917
47

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Fit the hollow drift, hydraulic cylinder and hydraulic pump to the spindle.
Special tools: 9990120, 9992671, 9996222
48
Press out the reversing shaft.
49
Remove the oil pump with the reverse gear pinion.
50

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Remove the rear cover for the main shaft and where applicable the oil pipe for the overdrive gear.
51
Remove the adjustment shim for the main shaft.
52
Turn the gearbox so that the input shaft (the shaft with discs) faces upwards.
53

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Remove the clip securing the air hose in the clutch cylinder. Carefully remove the clamps for the electrical cable and
the air hose to the clutch cylinder. Remove the three clutch cylinder screws.
54

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Remove the air hose for the clutch cylinder and the air pipe for the countershaft brake.
55

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Remove the countershaft brake.
56

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Remove the piston A and spring B for the countershaft brake.
57
Remove the clutch housing.
58

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Remove the air pipe nipple for the countershaft brake pipe.
59
Remove the sleeve from the intermediate shaft.
60
Remove the magnet located between the clutch housing and the lower part of the base housing. Clean the magnet.
61

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Prepare the lifting tool as illustrated. Use the two lifting arms and the spacer ring from special tool 9990028, lifting arm
kit 88800006, fixture plate and chain. Fit the lifting tool into the shaft assembly.
Special tools: 88800006, 9990028, 9996239, 9996910
62
Make a wooden fixture as illustrated to receive the shaft package.
Note: The main shaft must not be placed on a workbench or similar. This can damage the gear teeth. Therefore all
work must be carried out with the main shaft upright.
63

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Carefully lift out the shaft assembly and place it in the wooden fixture.
64
Remove the lifting tool from the shaft assembly.
65

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Pull the countershaft outer race out of the clutch housing. Use a puller, yoke, cylinder, pump and spindle.
Note: Only remove the outer race if the bearing will be changed.
Special tools: 88800033, 88800035, 9992671, 9996041, 9996222
66

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Pull the input shaft outer race out of the clutch housing. Use a puller, yoke, cylinder, pump and spindle.
Special tools: 88800033, 88800034, 9992671, 9996041, 9996222
67

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Drive the outer race of the countershaft rear bearing out of the gearbox housing. Use a drift and handle.
Special tools: 9992000, 9992215
68
Drive the outer race of the main shaft rear bearing out of the gearbox housing. Use a drift and handle.
Special tools: 9992613, 9996176
69

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Remove the oil screen and the overflow valve.
Inspection
70
Clean all parts. Check bearings, shafts, gears and synchronizers for damage and wear. Replace damaged or worn
parts.
Caution
New bearings and bearing races must be taken from the same box.
71
Lubricate all parts with gearbox oil before installation.
Assembly
72

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Drive the outer race of the main shaft rear bearing into the housing until the outer race is about 5 mm above the bottom
of the gearbox housing. Do the same thing for the outer race for the countershaft.
If the outer races have not been removed, they should be tapped out so that they are about 5 mm above the bottom of
the gearbox housing.
Note: This step must be performed to ensure that the measurements of the shaft assembly will be correct.
73
Turn the gearbox over 1/2 turn. Fit the oil screen and overflow valve. Torque tighten the valve.
Other special equipment: 1159794
Specifications:

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45 ± 5 Nm
74
Assemble the shaft assembly. Secure the lifting tool to the shaft assembly. Lubricate all bearings.
Note: It is important that the bearings are oiled, to give the correct clearances.
Special tools: 88800006, 9990028, 9996239, 9996910
75
Carefully lift the shaft assembly into the gearbox housing.
76
Remove the fixture and the three lifting arms from the shafts.
77

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Install the nipple for the air pipe for the countershaft brake.
78
When changing the countershaft outer race in the clutch housing, press it in so that it bottoms in the clutch housing.
Use a cylinder, drift, hollow drift and spindle.
Special tools: 9992003, 9996041, 9996042, 9992671, 9996222
79

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When changing the input shaft outer race in the clutch housing, press it in so that it bottoms in the clutch housing. Use
a cylinder, pump, drift, hollow drift and spindle.
Special tools: 9992671, 9996041, 9996042, 9996081, 9996022, 9998401
80
Apply Volvo-recommended high-temperature liquid gasket to the main housing's mating surfaces to the clutch housing
according to the illustration. Fit the magnet.

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81
Put the clutch housing on the base housing. Make sure that the guide dowels enter their holes in the clutch housing.
82
Install the clutch housing screws and torque tighten them alternately.
Specifications:
110 ± 10Nm
83
Remove the seal for the input shaft. Use a lever.
Note: Replace the seal if necessary.
84

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Press in the seal with a drift.
Note: Fill the space between the seal lips to 1/3 with a Volvo approved grease. Avoid getting grease on the felt ring. Oil
in the sealing ring mating face to the input shaft before assembly.
85
Turn the gearbox 1/2 turn.
86
When measuring the main shaft and countershaft the 2 LS gear must be engaged. fit screw 9996917 on to the main
shaft and screw 9996483 on the countershaft.
Without overdrive: The splitter gear clutch ring in its forward position.
With overdrive: The splitter gear coupling cone in itsrearmost position.
Note: The countershaft brake and oil pump must not be installed.
87

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Install a shim which is 0,9 mm thinner than the original shim on the mainshaft.
88
Lubricate the sealing ring and install the rear cover.

Torque tighten diagonally.
Specifications:
40±5 Nm
89
Install the countershaft cover, with a shim. The shim should be 0,9 mm thinner than the original shim. Fit the screws
and torque tighten them diagonally.
Specifications:
40±5 Nm
90
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.
Note: The countershaft brake must not be engaged.
91

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Lock the gears with the holder for the clutch sleeves.
92
Fit screw 9996917 on the main shaft and screw 9996483 on the countershaft.
Special tools: 9996917, 9996483
93

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Rotate the shafts 20 turns.
94
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
95
Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off the backlash at the marked
position and note it.
96
Turn the gearbox 1/2 turn. Remove the main shaft cover. Place a shim that is between 0.1 and 0.2 mm thicker than the
measured play together with the existing shim.
This gives a preload of between 0.1 and 0.2 mm.
Install the mainshaft cover.
Note: Torque tighten the screws diagonally.

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Specifications:
40±5 Nm
97
Rotate the shafts 20 turns.
98
Turn the dial gauge to the countershaft. The tip of the dial gauge should touch the countershaft. Zero the dial gauge
and mark up the measurement point.
99
Turn the gearbox over 1/2 turn.
100
Lift the tip of the dial gauge and rotate the countershaft at least 20 turns. Read off the clearance from the marked
measurement point and note the value.
101
Turn the gearbox 1/2 turn. Remove the countershaft cover. Place a shim that is between 0.1 and 0.2 mm thicker than
the measured play together with the existing shim.
This gives a preload of between 0.1 and 0.2 mm.
Install the countershaft cover.
Note: Torque tighten the screws diagonally.
Specifications:
40±5 Nm
102

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Remove
Dial indicator 9989876

Magnetic stand 9999696
Bolt 9996917
Bolt 9996483
Special tools: 9989876, 9999696, 9996917, 9996483
103
Remove the counter shaft cover.
104
Fit a new gasket on the oil pump.

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105
Install the oil pump. Hammer the reversing shaft into the gearbox housing using a plastic mallet. Fit the screws into the
reversing gear and torque tighten.
Note: Make sure that the bevel for the rotation lock is in the correct position.
Specifications:
48±8 Nm
106
Install the counter shaft cover. Fit the screws and tighten them diagonally.
Specifications:
40±5 Nm
107
Where applicable fit the overdrive oil pipe.
108

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Press in the synchronizer for high range.
Special tools: 9990015, 9992671, 9996081, 9996022, 9996315, 9998542
109
Fit both the washer halves.
110

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Fit the high range circlip.
111
Remove the forks 9990029 holding the clutch sleeves in place.
112
Oil and fit new O-rings. Install the oil distribution piping. Torque tighten the oil distribution piping. Use a socket.
Specifications:
250 ± 35 Nm
113

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Apply Volvo-recommended high-temperature liquid gasket.
114
Fit the adapter and lifting eye into the range section output shaft. Position the range housing over the main housing.
Lower and line up the piston rod and planet wheel. Secure the range housing. Torque tighten the bolts.
Note: Insert the guide pins 9996876 into the gearbox housing to facilitate the assembly.
Special tools: 9996479, 9996876, 9996925
Specifications:

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110 ± 10Nm
115
If the gearbox is equipped with a retarder, perform steps 116 – 121. Otherwise go to step 122.
116
Fit the retarder with a new O-ring, greased with silicon grease. Guide the bolts into the holes and lower the retarder
into position. Fit the nuts and tighten them by hand as illustrated in the order A, B, C and finally D.
Torque tighten the nuts in the same order.
Then angle-tighten the nuts 45° in the same order.
Then angle-tighten the nuts another 45° in the same order.
Note: After the retarder has been tightened, there should be a gap between the retarder and the range housing.
Specifications:
30 Nm
45°
117
118
Install new O-rings on the heat exchanger and the range housing. Apply silicon grease to the O-rings.
119

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Lift up the heat exchanger so that the narrow parts are guided into their respective holes. Fit the securing bolts. Pull
the heat exchanger in with the upper rear screws. Torque tighten the bolts.
Specifications:
85 Nm
120
Fit the temperature sensor for the retarder.
121

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Clamp the retarder wiring.
122
Install the blocking body, spring and plug for the range function.
123

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Install the oil filter housing with a new seal and a new oil filter. Where applicable, fit the oil cooler. Torque tighten the
bolts.
Specifications:
20 ± 3Nm
124
125
Fit a new gasket between the brake and the clutch housing.
126

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Add the discs alternately. Begin and end with a steel disc (two friction discs and three steel discs).
127
Fit the sleeve with a new O-ring, spring and piston.
128

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Fit the cylinder over the disc assembly and torque tighten the screws.
Specifications:
45 ± 5 Nm
129
Clean the nipple threads. Fit the brake pipe. Screw the nuts fully on by hand. Then tighten with a socket spanner a
further 3/4 turn.
130
Fit the clutch cylinder and air hose. Secure the hose with a clip. Torque tighten the bolts.

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Specifications:
45 ± 5 Nm
131
132
Fit the magnetic stand and dial gauge on the holder. Check the runout in the gear wheel. The measuring tip of the dial
gauge must be 2 mm below the teeth. The maximum permitted runout is 0.4 mm.
Special tools: 9999696, 9989876, 9990029
133
Fit a new seal to the control housing.
134
Insert the dowels into the gearbox housing.

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135
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 rear position and the range gear is set to high range (with the range shaft in its forward
position and the piston in the range cylinder in its innermost position) and that the shift forks in the control housing are
matched to the clutch rings. This is to enable the control housing to be fitted.
136
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.
137
Remove the guide pins.
138
Install the control housing screws and torque tighten them diagonally.
Specifications:
110 ± 10Nm
139
Connect VCADS, calibrate the gearbox and select perform test to check that the gearbox is working properly.
140
Remove the gearbox from the overhaul stand.

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141
Remove the fixture from the gearbox. Install the valve assembly. Clamp the air hose and electrical wiring.

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IMPACT 3.

0 Friday, 2 July 2010

43187-4 Gearbox, disassemble-inspect-assemble

Other special equipment: 1159794, 1159795

COPYRIGHT © Copyright Volvo Parts Corporation

Note: Plug nipples and valves during high pressure washing.

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

If it is not possible to engage reverse gear, engage 2nd or 3rd gear.

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

Special tools: 9986485, 9990031, 9996905, 9999737

COPYRIGHT © Copyright Volvo Parts Corporation

Drain the gearbox oil.

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the oil filter cover and guide sleeve.

Note: There will be a little oil left in the cover.

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the retarder wiring cable ties.

COPYRIGHT © Copyright Volvo Parts Corporation

Fit counterhold 9998570.

Special tools: 9998570

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the companion flange.

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

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the range housing securing screws.

Special tools: 9996479, 9996925

COPYRIGHT © Copyright Volvo Parts Corporation

Special tools: 9998051

Remove the oil distributor pipe. Use a socket.

Special tools: 9990027

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the circlip securing the high range synchronizer.

Remove both halves of the washer.

Special tools: 88800015

COPYRIGHT © Copyright Volvo Parts Corporation

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

Special tools: 9996222

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the reversing shaft centre screw.

Fit the puller and spindle to the reversing shaft.

Special tools: 9996315, 9996917

COPYRIGHT © Copyright Volvo Parts Corporation

Special tools: 9990120, 9992671, 9996222

Remove the oil pump with the reverse gear pinion.

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the adjustment shim for the main shaft.

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the countershaft brake.

COPYRIGHT © Copyright Volvo Parts Corporation

Remove the piston A and spring B for the countershaft brake.

COPYRIGHT © Copyright Volvo Parts Corporation