Service BulletinVolvo Truck CorporationCuritiba, Brazil Trucks

Date Group No. Release Page

9.2010 431 305 02 1(18)

Main shaft, overhaul

FM, FH

AT2412D, AT2612D, ATO2612D

AT2812D, ATO3112D

Main shaft, overhaul

T4012351

This service bulletin contains instructions for renovating the main shaft when removedfrom the vehicle.

88990193ENG44365 English

Printed in Sweden

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 2(18)

Service Procedures

43173-5Main shaft, overhaul

Unit removedAs the same illustrations are reused for different variants, some details may differ for thevariant you are working on. The essential information in the illustrations is, however,always correct.

Contents

Disassembly, page 2 Check, page 9 Assemble, page 9

Special tools: 9990030, 9992500, 9992619,9992621, 9992671, 9992911, 9994731,9996154, 9996222, 9996454, 9996480,9996498, 9996499, 9996500, 9996600,9996602, 9996603, 9996635, 9996725,9996904, 9998215, 9998393, 9998542

Other special equipment 1159796

Disassembly1

T4019291

1

Note: The main shaft is not to be laid on a bench orsimilar. This is to avoid the tooth wheels from beingdamaged. All work should be carried out with the shaftstanding.

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 3(18)

2

T4019123

2Remove the synchronizing ring and the synchronizingcone for the splitter.

3

T4019124

3Take off the support bearing.

9994731, 9996222, 9996454, 9996600, 9996602,9996603, 9996635, 9998215

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 4(18)

4

T4017289

4If there is clearance between the bearing and thepuller, insert five pieces of brass, 10x21x1.2 mm, inthe bearing.

5

T4019125

5Remove the nut by hitting the socket so that the shockreleases it.

9996480

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 5(18)

6

T4019126

6Pull off the HP wheel (3rd). Remove the spacer ringand the engaging sleeve.

9992619, 9992671, 9996222, 9998542

7

T4019127

7Pull off the hub for 2nd.

9990030, 9992619, 9992671, 9996222

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 6(18)

8

T4019128

8Remove 2nd gear and the needle bearing.

9

T4019129

9Pull off 1st gear and the tooth wheel and the bearingrace for 2nd gear. Remove the needle bearing.

Note: Ensure that there is a small amount of clearancebetween the gearwheel and the arms so that thegearwheel is not damaged.

9992619, 9992671, 9996222, 9996498, 9996499,9996500

1010Remove the engaging ring.

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 7(18)

11

T4021262

11Turn the shaft over and fit it carefully in the puller9990030.

9990030

12

T4021251

12Pull off reverse gear, bearing and spacing sleeve withpiston rings. Remove reverse gear needle bearing.

9990030, 9992621, 9992671, 9996222, 9996454,9996498, 9996499, 9996500

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 8(18)

13

T4021259

13Knock the spacing sleeve out of the bearing. Use asleeve mandrel as support if necessary.

9992911

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 9(18)

Check14

14Clean and inspect all components.

1515Oil in all the needle bearings, ball bearings and gearswith transmission oil when reassembling.

Assemble16

16Place the main shaft in the press with the sun gearfacing upwards.

1717Fit the reverse gear needle bearing.

18

T4019134

18Fit the reverse gear with the engaging teeth turneddownwards.

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 10(18)

19

T4022469

19Press on the rear bearing.

9996725

20

T4034846

20Carefully press on the spacing sleeve with the pistonrings.

Note: Pressing on the spacing sleeve can only bedone with the inner chamfer of the sleeve, otherwisethe piston ring groove can be damaged. It is thereforeimportant to use the correct tool.

9998393

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 11(18)

21

T4060865

21Turn over the shaft and fit the engaging sleeve for1st/reverse. Fit the needle bearing and 1st gear withthe engaging sleeve teeth turned downwards.

22

T4019139

22Manually install the toothed wheel with the flange facingdownwards until it passes the lubrication channel of themain shaft. Then install the needle bearing race forthe 2nd gear. Install the bearing race and the toothedwheel using tool 9996904 .

9996904

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 12(18)

23

T4019140

23Fit the 2nd gear needle bearing and then 2nd gear withthe teeth for the engaging sleeve facing up.

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 13(18)

24

T4019141

24Press on the hub for 2nd gear using tool 9996904.

9996904

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 14(18)

25

T4019142

25Fit the engaging sleeve for the HP wheel, 3rd gear.

26

T4019143

26Press on the rear bearing for the HP wheel, 3rd gear,using tool 9992500

9992500

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 15(18)

27

T4019144

27Fit the distance ring.

28

T4019145

28Fit the HP wheel (3rd) with the larger coupling teeth(for the splitter) turned upwards and the rounded teethdownwards.

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 16(18)

29

T4019146

29Press on the front bearing for the HP wheel using tool9992500.

Note: The bearing, spacing sleeve and gear arereplaced as a single unit.

9992500

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 17(18)

30

T4019147

30Fit the nut and socket wrench. Hold the shaft in thepress with a load of approx. 10 tonne. Tighten the nutto a torque of 40050 Nm. Use tool 9996480.

9996480115979640050 Nm

31

T4018299

31Remove the socket, hold the shaft securely and lockthe nut by punching a lug.

Note: Use a punch with a rounded point. Make sure itdoes not crack.

Volvo Truck Corporation Date Group No. Release PageService Bulletin 9.2010 431 305 02 18(18)

32

T4019148

32Press on the support bearing, using tool 9996154

9996154

33

T4019123

33Fit the synchronizing cone and the synchronizing ringfor the splitter.