IMPACT 4.08.

02 26/02/2025

Chassis ID Path
A 738492 4311/Repair//Gearbox, disassemble-inspect-assemble. Gearbox removed

Model Identity
FM 176602981

Publish date ID/Operation

09/02/2024 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.

Note: For replacement of GCU (Gear Control unit) or TECU, read first - MID 130 PID 160 Parameter setting .

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, (2x) 9990031, 9990120, 9992000, 9996081, 9992337,
9992613, 9992619 , 9992671, 9996041, 9996042, 9996081, 9996176, 9996222, 9996239, 9996041, 9996479,
9996483, 9996876, 9996889, 9996901, 9996905, 9996910, 9996917, 9996925, 9998051, 9998401, 9998542,
9999696, 9999737, 88800005, 88800006, 88800015, 88800033, 88800034, 88800035, 9992003, 88890206

Contents
Disassembly.
Inspection.
Assembly.

Disassembly
Important information before disassembling the gearbox.

Important information before disassembling the gearbox, check the condition of the clutch housing and basic
housing.

The following checks must be carried out during the procedure:

1. Check if there is any axial play in the main shaft and countershaft. It must be less than 0.25 mm.
If the axial play is greater than 0.25 mm, replace the clutch housing and bearings with new parts with
locking pins. See step61.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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 4.08.02 26/02/2025

2. Check the bearing's outer races for the input shaft and countershaft in the clutch housing. They must be
held still and not be able to rotate at room temperature.
If the bearing rotates: apply Loctite 638 (P/N 1161370). See step81.
3. Check the distance between the basic housing and the bearing's outer race on the main shaft and the
countershaft. Use a feeler gauge 0.05 mm thick and with a maximum width of 10 mm. It must not be
possible to insert the feeler gauge.
1. If the feeler gauge can be inserted, replace the basic housing, caps and bearings.
2. If the feeler gauge cannot be inserted: check rotation of the bearing outer race.
If the outer bearing race rotates: replace the two caps and bearings for ones with locking pins. In this
case, do not replace the base housing and clutch housing.
See step67.

The following measures must be carried out based on the results of the above checks:

If criteria 1 is not met, the gearbox must be updated to the variant with locking pin for the outer bearing races, on
both the clutch housing and the base housing. See step91–92and98–99.
If criteria 2 is not met, apply Loctite 638 (p/n 1161370).
If in criteria 3 it is not possible to insert a 0.05 mm, 10 mm long feeler blade, but the bearing is rotating, the rear
bearings for the main shaft and counter-shaft and the rear caps must be replaced with new bearings and caps
with locking pins. In this case, do not replace the basic housing.
If in criteria 3 it is possible to insert the 0.05 mm feeler gauge blade, replace the basic housing, plus the rear
bearings for the main shaft and counter-shaft and the rear caps for the beakers and caps with locking pin.

Note: if the gearbox already had bearings and rear caps with locking pins, these parts will be replaced only
when they are faulty.

On older gearboxes with long mileages, the existing parts can be reconditioned and the bearing's outer races
glued in the clutch housing. Use glue P/N 1161370.

Note! The bearing's outer races in the basic housing must not be glued due to the adjustment of the bearing
pretensioning.

The above upgrading to a variant with locking pins for the bearing's outer races requires a number of parts to be
replaced at the same time.

Clutch housing with locking pins

Complete front bearing, both for the main shaft and countershaft, with recess for the locking pin in the outer
bearing race.
Complete rear bearing, both for the main shaft and countershaft, with recess for the locking pin in the outer
bearing race.
Cover for main shaft with locking pin.
There are two different covers depending on version of gearbox ventilation. For more information read chapter
ventilation in Gearbox, manual .
Cover for countershaft with locking pin
Screws for cover, both for the main shaft and countershaft
Shims for adjusting the pretension for both the main shaft and countershaft

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

1
Clean the outside of the gearbox.

Note: Plug nipples and valves during high pressure washing.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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Connect the Tech Tool with brake out harness 88890206 and pressurized air, follow the guidelines for gear change
activation(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 step14if the Tech Tool program makes contact with TECU. Otherwise go to the next step.

Special tools: 88890206

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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Note: If the Tech Tool 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.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

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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IMPACT 4.08.02 26/02/2025

DD

OD
The figure shows where the various air ducts are that are used to manually operate the control housing air cylinders.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

DD

OD
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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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.

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IMPACT 4.08.02 26/02/2025

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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IMPACT 4.08.02 26/02/2025

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

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

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

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

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

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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IMPACT 4.08.02 26/02/2025

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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IMPACT 4.08.02 26/02/2025

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.

Note: It will be necessary (2x) 9990031.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

Special tools: 9986485, 9990031, 9996905, 9999737

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 some 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.

Special tools: 9992337

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

23

Fit the magnetic stand and dial gauge on the holder. Check the runout in the sensor 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

24
If the gearbox is equipped with a retarder, perform step25–27. Otherwise go to step29.

25

Remove the retarder's temperature sensor from the heat exchanger or alternatively, remove the connector from the
plate.

26

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Remove the retarder wiring cable ties.

27

Remove the three screws securing the heat exchanger and retarder cooler.

28
Carefully remove the heat exchanger and retarder cooler from gearbox.

29
Turn the gearbox so that the output shaft flange faces upwards.

30

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IMPACT 4.08.02 26/02/2025

Fit counterhold 9998570.

Remove the companion flange nut and O-ring.

Special tools: 9998570

31

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Remove the companion flange.

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

32

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

Remove the plug, spring and blocking body for the range function. If necessary use a magnet to pull out the blocking
body.

33
If the gearbox is equipped with a retarder, perform step34–35. Otherwise go to step36.

34

Remove the four nuts securing the retarder to the range housing (A, B, C and D in the illustration).

35
Carefully lift the retarder away from the gearbox.

36

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IMPACT 4.08.02 26/02/2025

Remove the range housing securing screws.

Note: If the gearbox has a retarder, do not forget to remove the screws from the retarder socket.

37

Fit the adapter and lifting eye into the output shaft.

Special tools: 9996479, 9996925

38

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IMPACT 4.08.02 26/02/2025

Split the main housing and range housing. Use press tool.

Special tools: 9998051

39
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.

40

Remove the oil distributor pipe. Use a socket.

Special tools: 9990027

41

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Remove the circlip securing the high range synchronizer.

42

Remove both halves of the washer.

43

Fit both the puller halves on to the high range synchronizer hub.

Special tools: 88800015

44

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IMPACT 4.08.02 26/02/2025

Install one part of puller 9998542 in the puller rings, with the hydraulic cylinder, threaded rod and peg.

Note: Ensure that the split in the puller rings is at 90° to the split in the puller.

Special tools: 88800015, 9992619, 9992671, 9996889, 9998542

45

Install the other part of puller 9998542. Install the hydraulic pump. Press off the high range synchronizer.

Special tools: 9996222

46

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Remove the reversing shaft centre screw.

47

Remove the countershaft cover and shim.

48

Fit the puller and spindle to the reversing shaft.

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IMPACT 4.08.02 26/02/2025

Special tools: 9996315, 9996917

49

Fit the hollow drift, hydraulic cylinder and hydraulic pump to the spindle.

Special tools: 9990120, 9992671, 9996222

50
Press out the reversing shaft.

51

Remove the oil pump with the reverse gear pinion.

52

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IMPACT 4.08.02 26/02/2025

Fit the shim and the countershaft cover.

53

Lock the gears with the holder for the clutch sleeves.

Note: When measuring the mainshaft and countershaft, gear 2 LS shall be engaged.
Without overdrive: The splitter gear clutch ring in its front most position.
With overdrive: The splitter gear clutch ring in its rear most position.
The countershaft brake must not be engaged.

Special tools: 9990029

54

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IMPACT 4.08.02 26/02/2025

Fit screw 9996917 on to the main shaft and screw 9996483 on the counter shaft.

Special tools: 9996917, 9996483

55

Rotate the shafts 20 turns.

56

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IMPACT 4.08.02 26/02/2025

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, 9989876

57
Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off a possible axial play at the
marked position and note it.

58

Turn the gearbox 1/2 turn. Attach the dial gauge to the counter shaft. The tip of the dial gauge should touch the
counter shaft. Zero the dial gauge and mark up the measurement point.

59
Turn the gearbox over 1/2 turn.

60
Lift the tip of the dial gauge and rotate the shafts at least 20 turns. Read off a possible axial play from the marked
measurement point and note the value.

61
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Check if there is any axial play in the main shaft and countershaft.
If the axial play is greater than 0.25 mm, replace the clutch housing and locking pin bearing with new parts.

Specifications:
Permissible end play: 0.25 mm

62
Turn the gearbox 1/2 turn.

63

Remove

Dial indicator 9989876

Magnetic stand 9999696
Bolt 9996917
Bolt 9996483

Special tools: 9989876, 9999696, 9996917, 9996483

64

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Remove the countershaft cover and shim.

65

Remove the main shaft cover and the overdrive's oil pipe where applicable.
Remove the main shaft shim.

66

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Remove the forks 9990029 holding the clutch sleeves in place.

Special tools: 9990029

67

Check the distance between the basic housing and the bearing's outer race on the main shaft and the countershaft.
Use a feeler gauge 0.05 mm thick and with a maximum width of 10 mm. It must not be possible to insert the feeler
gauge.

1. If the feeler gauge can be inserted, replace the basic housing, caps and bearings.
2. If the feeler gauge cannot be inserted: check rotation of the bearing outer race.
If the outer bearing race rotates: replace the two caps and bearings for ones with locking pins. In this case, do not
replace the base housing and clutch housing.
If the outer bearing race does not rotate: continue to step68.

Note: The measurement shall be performed at room temperature. The house should not be heated up to more than
30° C.

68
Turn the gearbox so that the input shaft faces upwards.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

69

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.

70

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IMPACT 4.08.02 26/02/2025

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

71

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IMPACT 4.08.02 26/02/2025

Remove the countershaft brake.

72

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IMPACT 4.08.02 26/02/2025

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

73
Remove the clutch housing.

74

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IMPACT 4.08.02 26/02/2025

Remove the air pipe nipple for the countershaft brake pipe.

75

Remove the sleeve from the intermediate shaft.

76
Remove the magnet between the clutch housing and the lower part of the basic housing. Clean the magnet.

77

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IMPACT 4.08.02 26/02/2025

Prepare the lifting tool as illustrated. Use two hoist arms and the spacer ring on special tool 9990028, hoist arm kit
88800006, fixing plate and chain. Fit the lifting tool into the shaft assembly.

Special tools: 88800006, 9990028, 9996239, 9996910

78

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.

79

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IMPACT 4.08.02 26/02/2025

Carefully lift out the shaft assembly and place it in the wooden fixture.

80
Remove the lifting tool from the shaft assembly.

81

Check the bearing's outer races for the input shaft and countershaft in the clutch housing.

Note: They must be held still and not be able to rotate at room temperature.

If the bearing rotates: apply Loctite 638 (p/n 1161370).

If the bearing does not rotate: continue to step82.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

Specifications:
p/n :1161370

82

Pull the countershaft's 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

83

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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IMPACT 4.08.02 26/02/2025

Pull the input shaft's 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, 88800034, 9992671, 9996041, 9996222

84

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
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.

42 / 78
IMPACT 4.08.02 26/02/2025

Remove the seal for the input shaft. Use a lever.

Note: Replace the seal if necessary.

Special tools: 9992337

85

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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43 / 78
IMPACT 4.08.02 26/02/2025

Drive the outer race of the countershaft rear bearing out of the gearbox housing. Use a drift and handle.

Note: Only remove the outer race if the bearing will be changed.

A = 9992000
B = 9996081

Special tools: 9992000, 9996081

86

Drive the outer race of the main shaft rear bearing out of the gearbox housing. Use a drift and handle.

Note: Only remove the outer race if the bearing will be changed.

Special tools: 9992613, 9996176

87

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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44 / 78
IMPACT 4.08.02 26/02/2025

Remove the oil screen and the overflow valve.

Inspection
88
The components must be washed clean and dried.

89
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.

90
Lubricate all parts with gearbox oil before installation. Refer to Gearbox and Retarder oil .

Assembly
91

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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45 / 78
IMPACT 4.08.02 26/02/2025

Check if the rear covers have locking pins fitted.

If they are provided with locking pins, note the position of the pins on the housing using a marker pen.

Alternatively, for older gearboxes with long mileages, the existing parts can be refitted.

92

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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46 / 78
IMPACT 4.08.02 26/02/2025

Align the groove in the outer races with the marked positions of the lock pins. 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 counter shaft.
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 carried out so that the shaft pretensioning can later be adjusted.

93

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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47 / 78
IMPACT 4.08.02 26/02/2025

Turn the gearbox over 1/2 turn. Fit the oil screen and overflow valve. Torque tighten the valve.

Specifications:
47 +5 / –3 Nm

94

Assemble the shaft assembly. Secure the lifting tool to the shaft assembly. Lubricate all bearings. Refer to Gearbox
and Retarder oil .

Note: It is important that the bearings are oiled, to give the correct clearances.

Special tools: 88800006, 9990028, 9996239, 9996910

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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48 / 78
IMPACT 4.08.02 26/02/2025

95
Carefully lift the shaft assembly into the gearbox housing.

96
Remove the fixture and the three lifting arms from the shafts.

97

Install the nipple for the air pipe for the countershaft brake.

98

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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49 / 78
IMPACT 4.08.02 26/02/2025

Check if the clutch housing is fitted with locking pins.

If it is provided with locking pins, note the position of the pins on the housing using a marker pen.

As an alternative, on older gearboxes with long mileages, the existing parts can be repaired and the bearing's outer
races glued in the clutch housing. Use glue P/N 1161370. Refer to Metal adhesive .

Note: The bearing's outer races in the basic housing must not be glued due to the adjustment of the bearing
pretensioning.

99

Align the groove in the outer races to the locking pin's marked positions.

100

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50 / 78
IMPACT 4.08.02 26/02/2025

Press the counter shaft outer race into the clutch housing, until it bottoms.

Special tools: 9992003, 9996041, 9996042, 9992671, 9996222

101

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51 / 78
IMPACT 4.08.02 26/02/2025

Press the input shaft outer race into the clutch housing, until it bottoms.

Special tools: 9992671, 9996041, 9996042, 9996081, 9996222, 9998401

102

Apply recommended sealing fluid for high temperatures to the main housing's contact surfaces on the clutch housing
as shown in the figure. Fit the magnet. Refer to Sealing agent (for engine, transmissions, cooling systems, hatches,
openings and covers) .

103
Place the clutch housing on the basic housing. Check that the guide pins locate in the holes in the clutch housing.

104
Fit the clutch housing screws and torque tighten them alternately.

Specifications:
110 ± 10 Nm

105

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52 / 78
IMPACT 4.08.02 26/02/2025

Press in a new sealing for the input shaft using a mandrel, (A) 88800211.

Note: Fill the space between the seal lips to 1/3 with a approved grease. Refer to Universal grease . Avoid getting
grease on the felt ring. Oil in the sealing ring mating face to the input shaft before assembly. Refer to Gearbox and
Retarder oil .

Special tools: 88800211

106
Turn the gearbox over 1/2 turn.

107

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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53 / 78
IMPACT 4.08.02 26/02/2025

Install a shim with thickness approximately 0.9 mm (standard thinner shim available).

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

When replacing the cover, where you have chosen not to do the recommended upgrade to the variant with locking
pins for the bearing outer races (see Important information before disassembling the gearbox.), do as follows:

For older variants without locking pins, the locking pins can be removed and the new cover with new screws can be
used.
For variants that have an O-ring fitted by the bearing, the O-ring must be discarded, the locking pin removed and the
new cover with new screws can be used.

108

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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54 / 78
IMPACT 4.08.02 26/02/2025

Fit the main shaft's cover with the shim.

Note: Torque tighten the screws diagonally, use new screws.

Note: There are two different covers (A and B) depending on version of gearbox ventilation. For more information read
chapter ventilation in Gearbox, mechanical .

Other special equipment: 88890148

Specifications:
40±5 Nm

109

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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55 / 78
IMPACT 4.08.02 26/02/2025

Install a shim with thickness approximately 0.9 mm (standard thinner shim available).

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

When replacing the cover, where you have chosen not to do the recommended upgrade to the variant with locking
pins for the bearing outer races (see Important information before disassembling the gearbox.), do as follows:

For older variants without locking pins, the locking pins can be removed and the new cover with new screws can be
used.
For variants that have an O-ring fitted by the bearing, the O-ring must be discarded, the locking pin removed and the
new cover with new screws can be used.

110

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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56 / 78
IMPACT 4.08.02 26/02/2025

Fit the countershaft's cover with the shim.

Torque tighten the screws diagonally.

Note: When replacing the cover, use new screws.

Specifications:
40 ± 5 Nm

111

Lock the gears with the holder for the clutch sleeves.

Note: When measuring the mainshaft and countershaft, gear 2 LS shall be engaged.
Without overdrive: The splitter gear clutch ring in its front most position.
With overdrive: The splitter gear clutch ring in its rear most position.
The countershaft brake must not be engaged.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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57 / 78
IMPACT 4.08.02 26/02/2025

Special tools: 9990029

112

Fit screw 9996917 on the main shaft and screw 9996483 on the countershaft.

Special tools: 9996917, 9996483

113

Rotate the shafts 20 turns.

114

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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58 / 78
IMPACT 4.08.02 26/02/2025

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

115
Turn the gearbox 1/2 turn. Lift the measuring probe and turn the shaft 20 turns, read off the axial play at the marked
position and note it.

116

Turn the gearbox 1/2 turn

Remove the main shaft's cover and shim (0.9 mm standard shim).

Note: There are two different covers (A and B) depending on version of gearbox ventilation. For more information read
chapter ventilation in Gearbox, mechanical .
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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59 / 78
IMPACT 4.08.02 26/02/2025

117

Pick up the measured clearance read on Step115, sum up the number 0.9 mm (standard thinner shim available used
on Step115) and finally sum up 0.1 or 0.2 mm.
The result of this sum will be the most approximately shim available in the tolerance range to be used.
This will gives a pretensioning of between 0.1 and 0.2 mm.

Note: Use only one shim. If the sum (measured clearance + standard shim 0.9 mm + 0.1 or 0.2 mm) results in a
different number of an existing shim, use the immediately thicker shim above the sum available in the tolerance range.

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

118
Where applicable fit the overdrive oil pipe.

119

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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60 / 78
IMPACT 4.08.02 26/02/2025

Fit the main shaft's cover with the new shim.

Note: Torque tighten the screws diagonally, use new screws.

Note: There are two different covers (A and B) depending on version of gearbox ventilation. For more information read
chapter ventilation in Gearbox, mechanical .

Specifications:
40 ± 5 Nm

120

Rotate the shafts 20 turns.

121

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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61 / 78
IMPACT 4.08.02 26/02/2025

Attach the dial gauge to the counter shaft. The tip of the dial gauge should touch the counter shaft. Zero the dial gauge
and mark up the measurement point.

122
Turn the gearbox over 1/2 turn.

123
Lift the tip of the dial gauge and rotate the shafts at least 20 turns. Read off the axial play from the marked
measurement point and note the value.

124
Turn the gearbox over 1/2 turn.

125

Remove

Dial indicator 9989876

Magnetic stand 9999696
Bolt 9996917
Bolt 9996483

Special tools: 9989876, 9999696, 9996917, 9996483

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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62 / 78
IMPACT 4.08.02 26/02/2025

126

Remove the countershaft cover and shim (0.9 mm standard shim).

127

Pick up the measured clearance read on Step123, sum up the number 0.9 mm (standard thinner shim available used
on Step123) and finally sum up 0.1 or 0.2 mm.
The result of this sum will be the most approximately shim available in the tolerance range to be used.
This will gives a pretensioning of between 0.10 and 0.25 mm.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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63 / 78
IMPACT 4.08.02 26/02/2025

Note: Use only one shim. If the sum (measured clearance + standard shim 0.9 mm + 0.1 or 0.2 mm) results in a
different number of an existing shim, use the immediately thicker shim above the sum available in the tolerance range.

Note: The recess in the shim must be aligned with the locking pin in the cover. To guarantee the location, fix the shim
in the cover using grease before fitting the cover.

It is recommended to use a shim with an existing recess for the locking pin.
When using a shim without a recess, a recess must be made for the locking pin as shown in the figure.

Note: There must be no burrs on the shim.

128

Fit a new gasket on the oil pump.

129

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.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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64 / 78
IMPACT 4.08.02 26/02/2025

Note: Make sure that the bevel for the rotation lock is in the correct position.

Specifications:
48 ± 8 Nm

130

Fit the countershaft's cover with the new shim measured on Step127.
Torque tighten the screws diagonally.

Specifications:
40 ± 5 Nm

131

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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65 / 78
IMPACT 4.08.02 26/02/2025

Press in the synchronizer for high range.

Note: It will be necessary to fit tool 9996917 as in step112.

Special tools: 88800015, 9992671, 9996081, 9996222, 9996315, 9998542, 9996917

132

Fit both the washer halves.

133

Fit the high range circlip.

Note: The circlip is available in seven thicknesses. Choose the thickest circlip that assures a residual play of maximum
0.05 mm.

134

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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66 / 78
IMPACT 4.08.02 26/02/2025

Remove the forks 9990029 holding the clutch sleeves in place.

Special tools: 9990029

135

Oil and fit new O-rings. Refer to Gearbox and Retarder oil . Install the oil distribution piping. Torque tighten the oil
distribution piping. Use a socket.

Special tools: 9990027

Specifications:
250 ± 35 Nm

136

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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67 / 78
IMPACT 4.08.02 26/02/2025

Apply approved high-temperature liquid gasket. Refer to Liquid Gasket .

137

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:
110 ± 10 Nm

138

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68 / 78
IMPACT 4.08.02 26/02/2025

Replace the V-ring on the companion flange. The V-ring must lie flush with the stop on the companion flange.

Note: Check the mating surface of the companion flange to ensure that there is no visible damage.

139

Press the companion flange onto the shaft.

Note: Under no circumstances may the companion flange be heated up or hit with a hammer.
The companion flange must be fitted and pressed onto the output shaft using the specified special tool.
It is of the greatest importance that the companion flange be pressed home completely before the nut is tightened.
If the companion flange is not pressed home properly, the output shaft bearing or the range oil pipe may be damaged.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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69 / 78
IMPACT 4.08.02 26/02/2025

A = 9996041; B = 9996901; C = 9996925; D = 9992671; E = 9996222.

Special tools: 9996041, 9996901, 9996925, 9992671, 9996222

140

Fit the counterhold onto the companion flange. Fit a new o-ring and a new nut.
Torque tighten the nut.

Special tools: 9998570

Specifications:
550 ± 50 Nm

141
Lock the nut.

Note: Use a center punch.

142
If the gearbox is equipped with a retarder, perform step143–148. Otherwise go to step149.

143

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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70 / 78
IMPACT 4.08.02 26/02/2025

Fit the retarder with a new O-ring, greased with silicon grease. Refer to Silicone 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°

144
Turn the gearbox 1/4 turn.

145
Install new O-rings on the heat exchanger and the range housing. Apply silicon grease to the O-rings. Refer to Silicone
grease .

146

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71 / 78
IMPACT 4.08.02 26/02/2025

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

147

Fit the temperature sensor for the retarder.

148

Clamp the retarder wiring.

149

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72 / 78
IMPACT 4.08.02 26/02/2025

Install the blocking body, spring and plug for the range function.

150

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:
26 ± 4 Nm

151
Turn the gearbox 1/4 turn.

152

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73 / 78
IMPACT 4.08.02 26/02/2025

Fit a new gasket between the brake and clutch housing.

153

Add the discs alternately. Begin and end with a steel disc (two friction discs and three steel discs).

154

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74 / 78
IMPACT 4.08.02 26/02/2025

Fit the sleeve with a new O-ring, spring and piston.

155

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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75 / 78
IMPACT 4.08.02 26/02/2025

Fit the cylinder over the disc assembly and torque tighten the screws.

Specifications:
45 ± 5 Nm

156
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.

157
Fit the clutch cylinder and air hose. Secure the hose with a clip. Torque tighten the bolts.

Specifications:
45 ± 5 Nm

158
Turn the gearbox 1/4 turn.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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76 / 78
IMPACT 4.08.02 26/02/2025

159

Fit the magnetic stand and dial gauge on the holder. Check the runout in the sensor 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

160
Fit a new seal to the control housing.

161

Insert the dowels into the gearbox housing.

Special tools: 9996876

162

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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77 / 78
IMPACT 4.08.02 26/02/2025

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.

163
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.

164
Remove the guide pins.

165
Install the control housing screws and torque tighten them diagonally.

Specifications:
110 ± 10 Nm

166
Connect the Tech Tool with brake out harness 88890206 and pressurized air.
Follow the guidelines in the Tech Tool to calibrate the gearbox and then gear change activation(for removal
/installation).

Other special equipment: 88890206

167
Remove the gearbox from the overhaul stand.

168
Remove the fixture from the gearbox. Install the valve assembly. Clamp the air hose and electrical wiring.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
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78 / 78