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

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.

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.

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.

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.

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.

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.

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.

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.

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

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.

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.

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.