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V o lv o T r u c k C o r p o r a tio n
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1 1 .2 0 1 0 4 3 2 1 4 4 0 6 1 (1 3 )

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C o n t r o l h o u s in g , r e m o v a l a n d in s t a lla t io n

A T 2 4 1 2 C , A T 2 5 1 2 C , A T 2 8 1 2 C ,
A T O 2 5 1 2 C , A T O 3 1 1 2 C
F M , F H

C o n tr o l h o u s in g , r e m o v a l a n d in s t a lla t io n

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T 4 0 2 1 2 0 7

• “ C o n t r o l h o u s in g , r e m o v e ” , p a g e 2

• “ C o n tr o l h o u s in g , in s t a ll” , p a g e 1 1

8 8 9 9 9 8 3 6
E N G 4 5 7 4 5 E n g lis h
P r in t e d in S w e d e n

V o lv o T r u c k C o r p o r a tio n D a te G ro u p N o . R e le a s e P a g e
S e r v ic e B u lle t in 1 1 .2 0 1 0 4 3 2 1 4 4 0 6 2 (1 3 )

S e r v ic e P r o c e d u r e s
4 3 2 2 2 -1
C o n tr o l h o u s in g , r e m o v e
N o te : T h e s a m e illu s t r a t io n s a r e re u s e d fo r d iffe r e n t
v a r ia n ts . S o m e d e ta ils m a y d iffe r fr o m th e v a r ia n t y o u
a re w o r k in g o n . H o w e v e r, t h e e s s e n tia l in f o r m a t io n in
th e illu s t r a t io n s is th e s a m e .

S p e c ia l t o o ls : 9 9 9 2 3 3 7
1
1
E n g a g e h ig h s p lit a n d h ig h r a n g e , t h is a p p lie s t o
g e a r b o x e s w ith o u t o v e r d r iv e .
E n g a g e lo w s p lit a n d h ig h r a n g e , t h is a p p lie s t o
g e a rb o x e s w ith o v e r d r iv e .

N o t e : T h e g e a r b o x m u s t b e i n h i g h s p li t a n d h i g h
r a n g e s o th a t t h e c o n t r o l h o u s in g fo r g e a r b o x e s w ith o u t
o v e r d r iv e c a n b e lifte d o u t.

N o t e : T h e g e a r b o x m u s t b e i n l o w s p li t a n d h i g h r a n g e
s o th a t t h e c o n tr o l h o u s in g fo r g e a r b o x e s w ith o v e r d r iv e
c a n b e lifte d o u t.

N o t e : M a k e s u r e t h e p a r k in g b r a k e is a p p lie d .

S e e V C A D S te s t: F u n c tio n G r o u p 4 0 0 0 , In fo r m a t io n
t y p e D ia g n o s t ic s G e a r s a c t iv a t io n , c o n t r o l h o u s in g ( f o r
r e m o v e / in s t a ll)

T 4 0 1 8 9 6 9 N o t e : I f V C A D S p r o h a s c o n ta c t w ith T E C U , p r o c e e d
to s te p 3 , o th e r w is e p r o c e e d to s te p 2 .
2
2

N o t e : If V C A D S p r o c a n n o t c o n ta c t th e T E C U , th e
c o n t r o l h o u s in g m u s t b e s e t t o t h e c o r r e c t p o s it io n f o r
r e m o v a l f r o m th e g e a r b o x m a n u a lly .

T h e _ g u r e s h o w s t h e p o s it io n s o f t h e v a r io u s c o n t r o l
h o u s i n g a i r c y lin d e r s t o a l lo w r e m o v a l o f t h e c o n t r o l
h o u s in g . T h i s is d o n e in t h r e e s te p s
• T h e s p litte r g e a r m u s t b e in its r e a r p o s itio n

• T h e r a n g e g e a r m u s t b e in its fr o n t p o s itio n
• R e v e r s e g e a r is s e le c te d in t h e g e a r b o x

T 4 0 2 1 6 4 6

3
3
R e m o v e t h e p r o p e lle r s h a ft f r o m th e ` a n g e o n th e
g e a rb o x .

V o lv o T r u c k C o r p o r a tio n D a te G ro u p N o . R e le a s e P a g e
S e r v ic e B u lle t in 1 1 .2 0 1 0 4 3 2 1 4 4 0 6 3 (1 3 )

4
4
R e m o v e t h e 1 3 s c r e w s t h a t h o ld t h e c o n tr o l h o u s in g
o n t o t h e g e a r b o x . R e m o v e t h e 5 s c r e w s h o ld in g t h e
c o v e r o n th e T E C U . T h e _ g u re s h o w s th e c o v e r s c re w s .

T 4 0 2 2 5 8 2

5
5
C a r e f u lly lift u p th e c o v e r a n d d is c o n n e c t th e c a b le
h a r n e s s b e t w e e n t h e c o v e r a n d c o n t r o l h o u s in g . .

T 4 0 2 0 5 9 7

6
6
In s t a ll 4 s c re w s (s e e _ g u r e ). T ig h te n th e s c re w s s o th a t
th e s u rfa c e o f th e c o n tro l h o u s in g is n o t d a m a g e d . T h is
is to e n s u r e th a t th e c o n tro l h o u s in g c a n n o t m o v e a n d
d a m a g e th e to o th e d w h e e l o n th e m a in s h a ft .

T 4 0 2 2 6 3 1

7
7
T h e _ g u r e s h o w s th e v a r io u s a ir c h a n n e l s th a t a r e u s e d
t o m a n u a lly c o n t r o l t h e c o n t r o l h o u s i n g ’s a i r c y lin d e r s .

C 4 0 3 4 7 7 5

V o lv o T r u c k C o r p o r a tio n D a te G ro u p N o . R e le a s e P a g e
S e r v ic e B u lle t in 1 1 .2 0 1 0 4 3 2 1 4 4 0 6 4 (1 3 )

D D

C 4 0 3 4 7 7 6

O D

8
8
P u t t h e s p lit t e r g e a r in it s r e a r p o s it io n u s i n g a
c o m p r e s s e d a i r n o z z le . P u t it i n t h e f o r w a r d p o s i t io n
_ r s t to c h e c k th a t th e s p l itte r g e a r m o v e s c o r r e c tly .

T 4 0 2 2 5 3 4

D D

T 4 0 2 2 5 3 3

V o lv o T r u c k C o r p o r a tio n D a te G ro u p N o . R e le a s e P a g e
S e r v ic e B u lle t in 1 1 .2 0 1 0 4 3 2 1 4 4 0 6 5 (1 3 )

O D

T 4 0 2 2 5 3 5

9
9
P u t th e r a n g e g e a r in its fr o n t p o s itio n u s in g a
c o m p r e s s e d a i r n o z z le . P u t it in t h e r e a r p o s it io n _ r s t t o
c h e c k th a t th e r a n g e g e a r m o v e s c o r r e c tly .

T 4 0 2 2 5 3 1

T 4 0 2 2 5 3 2

V o lv o T r u c k C o r p o r a tio n D a te G ro u p N o . R e le a s e P a g e
S e r v ic e B u lle t in 1 1 .2 0 1 0 4 3 2 1 4 4 0 6 6 (1 3 )

1 0
1 0
C h e c k if t h e g e a
s h a ft ` a n g e . If y
h o le s o th a t re v e
w ith th e n e x t s t e
r b o x is in n e u t r a l b y tu r n in g th e o u tp u t
o u c a n d o th a t , b l o w in th e r e v e r s e
r s e g e a r is e n g a g e d . If n o t, p r o c e e d
p .

C 4 0 3 4 7 7 7

1 1
1 1
I f y o u c a n ’t e n g a g e r e v e r s e g e a r , e n g a g e 2 n d o r 3 rd
g e a r in s te a d . It is n e c e s s a r y to p la c e 2 n d a n d 3 rd
a i r c y lin d e r s in n e u t r a l b e f o r e r e v e r s e g e a r c a n b e
e n g a g e d . N o t e th a t t h e r e is a m e c h a n ic a l in h ib ito r b u ilt
in t o th e c o n tr o l h o u s in g , th a t m a k e s it im p o s s ib l e t o
e n g a g e r e v e r s e i f t h e 2 n d a n d 3 r d a i r c y li n d e r s a re n o t
in n e u tr a l.

T 4 0 2 2 5 8 3

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V o lv o T r u c k C o r p o r a tio n D a te G ro u p N o . R e le a s e P a g e
S e r v ic e B u lle t in 1 1 .2 0 1 0 4 3 2 1 4 4 0 6 7 (1 3 )

1 2
1 2
U s e a n e x tra a ir n o z z le t o m o v e 2 n d a n d 3 r d a ir
c y lin d e r s in n e u tra l b y c a re f u lly b lo w in g in th e 2 n d a n d
3 r d h o le s w h ile tu r n in g th e o u tp u t s h a f t ` a n g e a lit t le ,
to c h e c k w h e n n e u t r a l is e n g a g e d .

T 4 0 2 2 5 3 7

T 4 0 2 2 5 3 8

1 3
1 3
U s e a n a ir n o z z le to e n g a g e r e v e rs e g e a r in th e
g e a rb o x .

C 4 0 3 4 7 7 7

1 4
1 4
T ilt u p t h e c a b u s in g t h e c a b t ilt p u m p .

V o lv o T r u c k C o r p o r a tio n D a te G ro u p N o . R e le a s e P a g e
S e r v ic e B u lle t in 1 1 .2 0 1 0 4 3 2 1 4 4 0 6 8 (1 3 )

1 5
1 5
D is c o n n e c t t h e p o w e r t o t h e v e h ic le . R e m o v e t h e
b a tte r y n e g a tiv e le a d .
1 6
1 6
L o o s e n th e s c r e w s fo r th e r e t a r d e r c o o la n t p ip e , if t h e r e
is o n e , t o m a k e it e a s ie r t o s lid e t o o n e s id e , w h ic h
m a k e s it e a s ie r to lift t h e c o n tr o l h o u s in g u p .

T 4 0 1 8 5 0 5

1 7
1 7
E m p ty th e p n e u m a tic s y s te m .
1 8
1 8
R e m o v e th e a ir p ip e fr o m t h e c o n t r o l h o u s in g .

T 4 0 1 8 5 0 8

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