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Service BulletinVolvo Truck CorporationGteborg, Sweden
Trucks
Date Group No. Release Page
11.2010 432 144 06 1(13)
Control housing, removal and installation
AT2412C, AT2512C, AT2812C,ATO2512C, ATO3112C
FM, FH
Control housing, removal and installation
T4021207
Control housing, remove, page 2 Control housing, install, page
11
88999836ENG45745 English
Printed in Sweden
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 2(13)
Service Procedures
43222-1Control housing, remove
Note: The same illustrations are reused for differentvariants.
Some details may differ from the variant youare working on.
However, the essential information inthe illustrations is the
same.
Special tools: 9992337
1
T4018969
1Engage high split and high range, this applies togearboxes
without overdrive.Engage low split and high range, this applies
togearboxes with overdrive.
Note: The gearbox must be in high split and highrange so that
the control housing for gearboxes withoutoverdrive can be lifted
out.
Note: The gearbox must be in low split and high rangeso that the
control housing for gearboxes with overdrivecan be lifted out.
Note: Make sure the parking brake is applied.
See VCADS test: Function Group 4000, Informationtype Diagnostics
Gears activation, control housing (forremove/install)
Note: If VCADS pro has contact with TECU, proceedto step 3,
otherwise proceed to step 2.
2
T4021646
2
Note: If VCADS pro can not contact the TECU, thecontrol housing
must be set to the correct position forremoval from the gearbox
manually.
The figure shows the positions of the various controlhousing air
cylinders to allow removal of the controlhousing. This is done in
three steps
The splitter gear must be in its rear position The range gear
must be in its front position Reverse gear is selected in the
gearbox
33Remove the propeller shaft from the flange on thegearbox.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 3(13)
4
T4022582
4Remove the 13 screws that hold the control housingonto the
gearbox. Remove the 5 screws holding thecover on the TECU. The
figure shows the cover screws.
5
T4020597
5Carefully lift up the cover and disconnect the cableharness
between the cover and control housing..
6
T4022631
6Install 4 screws (see figure). Tighten the screws so thatthe
surface of the control housing is not damaged. Thisis to ensure
that the control housing cannot move anddamage the toothed wheel on
the mainshaft.
7
C4034775
7The figure shows the various air channels that are usedto
manually control the control housings air cylinders.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 4(13)
DD
C4034776
OD
8
T4022534
DD
T4022533
8Put the splitter gear in its rear position using acompressed
air nozzle. Put it in the forward positionfirst to check that the
splitter gear moves correctly.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 5(13)
OD
T4022535
9
T4022531
T4022532
9Put the range gear in its front position using acompressed air
nozzle. Put it in the rear position first tocheck that the range
gear moves correctly.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 6(13)
10
C4034777
10Check if the gearbox is in neutral by turning the outputshaft
flange. If you can do that, blow in the reversehole so that reverse
gear is engaged. If not, proceedwith the next step.
11
T4022583
11If you cant engage reverse gear, engage 2nd or 3rdgear
instead. It is necessary to place 2nd and 3rdair cylinders in
neutral before reverse gear can beengaged. Note that there is a
mechanical inhibitor builtinto the control housing, that makes it
impossible toengage reverse if the 2nd and 3rd air cylinders are
notin neutral.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 7(13)
12
T4022537
T4022538
12Use an extra air nozzle to move 2nd and 3rd aircylinders in
neutral by carefully blowing in the 2nd and3rd holes while turning
the output shaft flange a little,to check when neutral is
engaged.
13
C4034777
13Use an air nozzle to engage reverse gear in thegearbox.
1414Tilt up the cab using the cab tilt pump.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 8(13)
1515Disconnect the power to the vehicle. Remove thebattery
negative lead.
16
T4018505
16Loosen the screws for the retarder coolant pipe, if thereis
one, to make it easier to slide to one side, whichmakes it easier
to lift the control housing up.
1717Empty the pneumatic system.
18
T4018508
18Remove the air pipe from the control housing.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 9(13)
19
T4018970
19Remove the electrical connections from the controlhousing and
mark them.
20
T4018971
20Remove the hydraulic hose between the two cablatches.
21
T4018972
21Remove the air filter.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 10(13)
22
T4020997
22Remove the air inlet bracket.
23
T4020998
23Remove the cab crossmember.
2424Remove the screws for the control housing.
25
T4018975
25Lift off the control housing carefully so that the toothwheel
in the gearbox is not damaged, use a crowbar,force it carefully so
that the control housing loosensfrom the locating pins.
9992337
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 11(13)
43224-1Control housing, install
Special tools: 9996876
11Install a new control housing seal.
2
T4018982
2Install the guide pins 9996876 in the gearbox housing.
9996876
3
T4021451
HR=high range
S=split
2/3=2nd/3rd gear in neutral
R=reverse gear
3Ensure that the split engagement ring is in its
rearmostposition and that 2nd/3rd engagement ring is in
neutralposition The reverse gear engagement ring shall be inits
rearmost position and the range gear in high range.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 12(13)
4
T4018984
4Carefully lower the control housing, to avoid damagingthe gear
wheel and ensure that the split engaging forkends up in the correct
position in the engaging ring.Carefully tap the control housing
down at the guidepins.
55Remove the guide pins.
66Install the control housing screws and torque themdiagonally
to 11010 Nm.
11010Nm
77Install the screws for the retarder coolant pipe if
fitted.
88Install the electric connectors as marked on the
controlhousing.
99Connect the air pipe to the control housing.
1010Install the cab crossmember and air filter bracket.
1111Install the hydraulic hose for the cab tip lock, vent
thesystem.
1212Install the air filter.
1313Fit the air inlet.
1414Connect the battery negative lead.
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Volvo Truck Corporation Date Group No. Release PageService
Bulletin 11.2010 432 144 06 13(13)
1515Fill the compressed air system with air and check thatno
leakage occurs.
1616Un-tilt the cab
1717Connect the PC tool to the vehicle and go to thefunction
group choice in the menu system.
1818Calibrate the gearbox, clutch travel, wear calibrationand
clutch engagement point.
1919Removing the PC tool.