IMPACT 3.

0 Thursday, 20 September 2012

Chassis ID Path
4/Repair/B12R, AT2412C/Control housing, overhaul. Removed

Model Identity
B12R 129814382

Publishing Date Operation No.

Friday, 5 November 2010 43278-4

43278-4 Control housing, overhaul

Removed

Note: Since illustrations are used for several different variants, certain details may differ from the variant in question.
The essential information in the illustrations is, however, always correct.

Copyright Volvo Group North America

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 3.0 Thursday, 20 September 2012

A. Position sensor for range cylinder R. Range cylinder

B. Countershaft speed sensor 2/3. 2/3 cylinder
C. Main shaft speed sensor 1/R. 1/R cylinder
D. Position sensor, 2nd and 3rd cylinder S. Split cylinder
E. Position sensor 1st and reverse
cylinder
F. Position sensor split cylinder

Part number: 1161053

Special tools: 9998588

Other special equipment: 1159794

Read off X1 value with the PC-tool or from the label, note X1 value.
This is in case the upper cover needs to be replaced. Remove all electrical connections (4) for the position sensors.

Copyright Volvo Group North America

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 3.0 Thursday, 20 September 2012

Remove the speed sensors for the main shaft and the countershaft.

Remove the screws from the electrical cable attachment plate.

Copyright Volvo Group North America

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 3.0 Thursday, 20 September 2012

Turn the control housing so that it is standing on the selector forks. Remove the upper cover screws (6 x M8x30).

Turn the control housing so that its front edge (split fork side) is against the bench.

Copyright Volvo Group North America

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 3.0 Thursday, 20 September 2012

Loosen the upper edge of the cover and carefully fold down towards the bench. Remove the electrical connector
carefully to avoid damaging the electrical cabling.

Remove the seals for the solenoid valves, the O-ring for the countershaft brake and the cover gasket.

Remove the electrical cable screws (hex socket screw). Remove the electrical cable carefully so that it is not damaged.

9
Turn the control housing so that the selector forks are turned upwards.

10

Copyright Volvo Group North America

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.

5 / 23
IMPACT 3.0 Thursday, 20 September 2012

Remove the locking keys for 2nd/3rd cylinder, 1/R cylinder and the split cylinder.

Note: The keys are spring-loaded (all the keys are similar).

11

Remove all 4 position sensors (all position sensors are similar).

12

Copyright Volvo Group North America

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.

6 / 23
IMPACT 3.0 Thursday, 20 September 2012

Remove the piston and sealing ring from the back of the split cylinder.

13

Remove the front cover for the 1/R cylinder, undo the rear cover and pull out the selector fork with covers and piston.

Note: The 2nd/3rd selector fork shall be in neutral position, so that the inhibitor pin for 1st/R and 2nd/3rd
cylinders does not lock the front cover in place.

14

Copyright Volvo Group North America

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.

7 / 23
IMPACT 3.0 Thursday, 20 September 2012

Remove the piston from the front of the 1st/R cylinder.

15

Loosen both covers for the 2nd/3rd cylinder. Pull out the selector fork with cover and piston. Remove the rear cover.

16

Remove the piston from the back of the 2nd/3rd cylinder.

17

Copyright Volvo Group North America

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.

8 / 23
IMPACT 3.0 Thursday, 20 September 2012

Remove the cover for the range cylinder. Pull out the piston carefully, so that the piston rod seal is not damaged.

Note: The bush and seal in the rear end plate of the range cylinder cannot be replaced separately and must therefore
be left in place.

18

Loosen both covers for the split cylinder. Pull out the selector fork with cover and piston. Remove the rear cover.

19
Clean the housing, check constituent parts. Change any damaged parts.
None of the seals or bushes in any of the covers can be replaced separately, therefore the whole cover must be
changed.

Note: Blow clean the air passages between the cylinders and solenoid valves thoroughly.
When assembling, all piston surfaces, piston sliding surfaces and sealing rings must be greased.

20

Copyright Volvo Group North America

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.

9 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit new sealing rings and support strips to the range piston. Grease sliding surfaces and sealing rings.

Note: Lips of the sealing ring.

21
Carefully fit the piston into the range cylinder, fit the cover with a new O-ring and torque tighten the bolts.

Other special equipment: 1159794

Specifications:
181.5 Nm

22

Copyright Volvo Group North America

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.

10 / 23
IMPACT 3.0 Thursday, 20 September 2012

Press out the spring pin for the 2nd/3rd selector fork. Use a drift and a sleeve as counterhold. Remove the selector fork
(carefully tap the spring pin out of the selector fork).

Note: Spring and pin for the position sensor.

Special tools: 9998588

23
Remove the cover and piston from the piston rod.

24
Fit a new piston and a new O-ring into the cover. Fit the cover onto the piston rod.

25

Copyright Volvo Group North America

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.

11 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit position sensor pins and springs to the selector fork.

26

Fit the 2nd/3rd selector fork onto the piston rod, press the piston rod to the bottom of the fork and carefully press in the
spring pin using a drift with a sleeve as support.

Note: The opening in the spring pin must be facing the cover and lengthwise in relation to the piston rod.

Special tools: 9998588

27

Copyright Volvo Group North America

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.

12 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit the 2nd/3rd selector fork with cover and piston into the 2nd/3rd cylinder. Fit the piston and rear cover with a new
O-ring. Torque tighten the screws.

Other special equipment: 1159794

Specifications:
181.5 Nm

28
Fit a new O-ring to the rear split cover. Fit the piston into the cylinder with a new piston seal. Fit the rear cover and
torque tighten the screws.

Note: This must be done now, because it is not possible to torque tighten the screws later.

Other special equipment: 1159794

Specifications:
181.5 Nm

29

Copyright Volvo Group North America

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.

13 / 23
IMPACT 3.0 Thursday, 20 September 2012

The 2nd/3rd selector fork is illustrated

Press out the spring pin for the 1st/R selector fork. Use a drift and a sleeve as counterhold.
Remove the selector fork (carefully tap the spring pin out of the selector fork).

Special tools: 9998588

30
Remove the cover and piston from the piston rod.

31
Fit a new piston onto the piston rod and a new O-ring onto the cover.

32

Copyright Volvo Group North America

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.

14 / 23
IMPACT 3.0 Thursday, 20 September 2012

The 2nd/3rd selector fork is illustrated

Fit the 1st/R selector fork onto the piston rod, press in the spring pin carefully using a drift with a sleeve as support.

Note: The opening in the spring pin must be facing the cover and lengthwise in relation to the piston rod.

Special tools: 9998588

33
Fit a new O-ring to the front cover.

34

Fit a new piston to the front of the cylinder for the 1st/R cylinder.

35

Copyright Volvo Group North America

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.

15 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit a new O-ring into the front cover of the 1st/R cylinder. Fit the locking pin into the cover.
Fit the cover and torque tighten the screws.

Other special equipment: 1159794

Specifications:
181.5 Nm

36
Fit the cover into the split cylinder.

37
Put the 2nd/3rd selector fork in neutral position and press in the locking pin against the 2nd/3rd selector fork so that it
engages in the groove for neutral.

38
Fit the selector fork with piston and cover into the 1st/R cylinder. Torque tighten the screws.

Other special equipment: 1159794

Specifications:
181.5 Nm

39

Copyright Volvo Group North America

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.

16 / 23
IMPACT 3.0 Thursday, 20 September 2012

Press the spring pin carefully out of the split selector fork. Use a drift and a sleeve as counterhold.
Remove the selector fork (carefully tap the spring pin out of the selector fork).

Special tools: 9998588

40

Remove the cover and change all the sealing rings on the pistons.

41

Copyright Volvo Group North America

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.

17 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit the cover onto the piston rod, fit the selector fork and press in the spring pin carefully using a drift and a sleeve as
support.

Note: The opening in the spring pin must be facing the cover and lengthwise in relation to the piston rod.

Special tools: 9998588

42
Fit the selector fork with piston into the split cylinder.

43
Fit the selector fork stop. Torque tighten the screws for the cover and stop.

Other special equipment: 1159794

Specifications:
181.5 Nm

44

Copyright Volvo Group North America

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.

18 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit the locking keys for 2nd/3rd cylinder, 1st/R cylinder and the split cylinder.

45

Fit all position sensors.

Torque tighten the screws.

Other special equipment: 1159794

Specifications:
70.7 Nm

46

Copyright Volvo Group North America

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.

19 / 23
IMPACT 3.0 Thursday, 20 September 2012

Grease the O-ring on the electric cable.

47

Turn the control housing so that its front edge (split fork side) is on the bench. Fit the electrical cable.

Note: Direction of electric cable.

Part number: 1161053

48

Copyright Volvo Group North America

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.

20 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit new seals to the solenoid valves, a new O-ring to the countershaft brake and a new gasket to the cover.

49

Connect the electrical cable for the cover.

Note: Ensure that the electrical cable is not damaged.

The front edge of the control housing must be against the bench. Fit the cover.

50

Copyright Volvo Group North America

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.

21 / 23
IMPACT 3.0 Thursday, 20 September 2012

Turn the control housing so that it is standing on the selector forks. Fit new screws to the cover (6 off M8x30, included
in repair kit) and torque tighten.

Other special equipment: 1159794

Specifications:
244 Nm

51

Turn the control housing so that the upper cover is against the bench.
Fit the attachment plate for the electrical cable. Connect the electrical cable to the position sensors.

Note: The electrical cable must lie inside the lug on the range cylinder.

52

Copyright Volvo Group North America

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.

22 / 23
IMPACT 3.0 Thursday, 20 September 2012

Fit the speed sensors.

Torque tighten the screws.

Other special equipment: 1159794

Specifications:
60.6 Nm

53
Perform a functional test Gear test, removed gearbox, in the PC-tool.

Note: Carry out the test with the control housing lying on the upper cover. The control housing must not be touched
during the test, due to the risk for injury.
Once the control housing has been fitted to the gearbox, calibration must be performed. If the cover has been
changed, the noted value for X1 must be entered into the control unit.

Copyright Volvo Group North America

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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