IMPACT 4.00.51.

00-SNAPSHOT 11/02/16

Chassis ID Path
A 651861 4313/Repair//Main shaft, overhaul. Unit removed

Model Identity
FH 131793145

Publish date ID/Operation

08/05/13 43173-5

43173-5 Main shaft, overhaul

Unit removed

Whilst the illustrations used in the Service Bulletins are valid for several variants, certain details may be different in the
variant you are working on. However, the essential information shown in the illustrations is accurate.

Removed

Special tools: 1159796, 9992500, 9992619, 9992621, 9992671, 9994731, 9996083, 9996156, 9996222, 9996280,
9996413, 9996454, 9996480, 9996498, 9996499, 9996500, 9996600, 9996602, 9996603, 9996635, 9996725,
9996901, 9996904, 9996924, 9998215, 9998216, 9998542, 9998661

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.

1 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

1 Support bearings

2 Nut

3 Bearing

4 Spacer ring

5 Synchronizing cone

6 Synchronizing ring

7 P1 wheel

8 Bearing

9 Engaging ring

10 Inner cone

11 Intermediate cone

12 Outer cone

13 Pusher

14 Engaging sleeve

15 Cup spring

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.

2 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

16 Guide sleeve

17 Spring

18 Detent pin

19 Spring

20 Detent pin

21 Lock plate

22 Retaining ring

23 1st gear wheel

24 Needle bearing

25 Retaining ring

26 Engaging ring

27 Inner cone

28 Intermediate cone

29 Outer cone

30 Pusher

31 Engaging sleeve

32 Cup spring

33 Guide sleeve

34 Spring

35 Detent pin

36 Spring

37 Detent pin

38 Cup spring

39 Pusher

40 Outer cone

41 Intermediate cone

42 Inner cone

43 Engaging ring

44 Needle bearing

45 2nd gear wheel

46 Main shaft

47 Needle bearing

48 Crawler gear

49 Hub

50 Engaging sleeve
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.

3 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

51 Inner ring

52 Needle bearing

53 Reverse gear wheel

54 Bearing

55 Piston rings

56 Spacer ring

57 Sun gear

All bearings that are reused must be fitted in their original positions and face the same way as when they were
removed.
All synchronizing components that are re-used must be put back in the same place as when they were removed.
Locking parts must not be mixed between the different synchromesh rings.
The outer and inner races of the conical bearings must be from the same manufacturer.

Disassembly
1
Remove synchronizing cone (5) and synchronizing ring (6) for the splitter gear.

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
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4 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Assemble the tools. Pull off the support bearing (1). If there is a gap between the bearing and puller 9998215, put five
pieces of brass 20x25x1.2 mm into the bearing.

9994731
9996222
9996413
9996454
9996600
9996602
9996603
9996635
9998215

Release the nut (2) by striking on 9996480 so that the staking comes away from the nut. Remove the nut.

Special tools: 9996480

4
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.

5 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Pull off the P1 wheel (7) and front bearing (3), remove the spacer ring (4) for the bearing.

Note: The bearings may be reused and their positions should therefore be marked when dismantling. P1 wheel (can be
fitted wrong way round).

Special tools: 9992671, 9996222, 9998542

5
Remove engaging ring (9), synchronizing cones (10, 11, 12) and pusher plate (13).

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.

6 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Assemble the tools. Pull off the other bearing (8) for the P1 gear wheel and synchronization (14-22) by pulling off the
1st gear wheel (23), remove the needle bearing (24).

Note: Hold the engaging sleeve so that the detent bodies and springs do not fall out.

Special tools: 9992619, 9992671, 9996156, 9996222, 9996498, 9996499, 9996500

7
Remove the 1st engaging ring (26) and the synchronizing cones (27, 28, 29).

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.

7 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Remove the retaining ring (25) for the 1st and 2nd guide sleeve.

Assemble the tools. Pull off the 2nd gear wheel (45), the guide sleeve will come with it. Remove the synchronization
(30-43), gear wheel (45) and needle bearing (44).

Note: Hold the engaging sleeve so that the detent bodies and springs do not fall out.

Special tools: 9992619, 9992671, 9996156, 9996222, 9996498, 9996499, 9996500, 9998661

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
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.

8 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Turn over the shaft (46). Assemble the tools and pull off the sun gear (57).

Special tools: 9994731, 9996222, 9996413, 9996454, 9996600, 9996602, 9996603, 9996635, 9998216

11

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.

9 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Assemble the tools. Pull off the reverse gear (53), bearing (54) and spacer ring (56). Remove the needle bearing (52)
and engaging sleeve (50) for crawler and reverse gears.

Special tools: 9992619, 9992671, 9996156, 9996222, 9996498, 9996499, 9996500

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
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.

10 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Press off the crawler gear (48), the inner ring (51) and hub (49) for crawler and reverse gear will come away at the
same time. Remove needle bearing (47).

13
Take apart the 1st, 2nd and 3rd gear synchronizing mechanisms, put a rag round the engaging sleeve so that the
detent pins (4 large and 2 small) and springs do not fall apart and onto the floor during disassembly.
Remove the retaining ring and pressure plate for 3rd gear.

Note: Do not mix up the detent components from the different synchronizing mechanisms.

Clean and check

14
Clean and inspect all components.

Note: Intermediate cones must not be washed.

15
Check wear surfaces on engaging rings, synchronizing rings and synchronising cones. Rings and cones with
completely or partially worn grooves and blued surfaces must be changed. Check the coupling teeth.

Note: The inner cones, intermediate cones and outer cones must all be changed when changing the synchronising
cones.

Assembly
All needle bearings, roller bearings, synchronizing cones and gear wheels must be oiled with gearbox oil when
assembling.
Replace the detent springs with new ones and oil them after assembly.

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.

11 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Assembly of 3:rd gear synchronizing

16

Place the engaging sleeve (14) on the workbench. With the protruding splines on the engaging sleeves pointing
upwards.

17

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.

12 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Press the guide sleeve (16) into the engaging sleeve with the retaining ring groove upwards.

Note: The large recesses on the guide sleeve (16) should fit the engaging sleeve (14) so that two splines are in each
recess on the guide sleeve.

18

Press the two springs (17) and the two small detent pins (18) in the guide sleeves. Press the guide sleeve into the
engaging sleeve.

19

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.

13 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Note: For the lock pins and locking plate refer to the illustration above; the numbers underneath the illustrations stand
for versions 1 and 2 (no gear); the different versions must not be mixed with each other. However, either may be used.

20

Place ring 9996280 as a base for the guide sleeve (16), which makes it easier to assemble the springs and detent pins.
Press the engaging sleeve (14) towards the bench, fit the four springs (19) and the four detent pins (20) from above.
Position the detent pins, using a drift from above and a finger from below if necessary.

Special tools: 9996280

21

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.

14 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put on the lock plate (21) with the folded tabs upwards, install the retaining ring (22) with the opening in front of the
uncut part of the plate.
Make sure that the retaining ring goes into the groove.

22

Pull up the engaging sleeve (14).

Note: Turn everything over very carefully.

23

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.

15 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put in the cup spring (15) with the lowest point against the guide sleeve neck.
(If you press on the outer edge of the cup spring it should lift from the opposite side).

Note: The inner diameter of the cup spring is 95 mm.

24

Put on the pressure plate (13) with the arms in one of the recesses.

25

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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16 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put the outer cone on (12) with the heels in the same position as the pusher plate arm.

26

Put in the intermediate cone (11).

27

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.

17 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put in the inner cone (10). Put the small recesses in the inner cone on the small heels on the pusher plate.

28

Put on the engaging ring (9) with the flat side up and the heels of the intermediate cone in the holes of the engaging
ring.

Note: The size of the engaging ring is 122.5 mm, see picture.

Assemble 1st and 2nd gear synchronization

29

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.

18 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Place the engaging sleeve (31) on the workbench. With the recess on the engaging sleeve upwards.

30

Put the guide sleeve (33) with the longer neck ( Ø 111 mm) facing upwards on the engaging sleeve.

Note: Two splines in each of the large recesses on the guide sleeve. The small recess on the guide sleeve should be
to the left of engaging sleeve recess.

31

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.

19 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Press the two springs (34) and the two small detent pins (35) into the guide sleeve (33), press the guide sleeve down
into the engaging sleeve.

32

Note: See illustration above for detent pins. Numbers under figures stand for versions 1 and 2 (not gears). Different
versions must not be mixed. Both can be used, however

33

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.

20 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Place ring 9996280 as a base for the guide sleeve, to make it easier to put in the springs and detent pins.
Press the engaging sleeve (31) towards the bench, fit the four springs (36) and the four detent pins (37) from above.
Position the detent pins, using a suitable drift from above and a finger from below if necessary.

9996280

34

Put in the cup spring (38) with the lowest point against the guide sleeve neck.
(If you press on the outer edge of the cup spring it should lift from the opposite side).

Note: The inner diameter of the cup spring is 112 mm.

35

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
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21 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put the pusher plate (39) onto the guide sleeve with one of the small heels on the pressure plate towards the recess on
the engaging sleeve.

36

Put the outer cone on (40) with the heels in the same position as the pusher plate arm.

37

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.

22 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put in the intermediate cone (41).

38

Put in the inner cone (26). Put the small recesses in the inner cone on the small heels on the pusher plate.

39

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.

23 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Place the engaging ring (26) with its flat side upwards, so that the intermediate cone lugs fit into the holes.

Note: The size of the engaging ring is 122.5 mm, see picture.

40

Pull the engaging sleeve up to neutral position. Be careful, so that the synchronizing package does not fall apart.

41

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.

24 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put in the cup spring (32) with the lowest point against the guide sleeve neck.
(If you press on the outer edge of the cup spring it should lift from the opposite side).

Note: The inner diameter of the cup spring is 117 mm.

42

Put the pusher plate (30) with the arms between the free recesses.

43

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.

25 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put the outer cone on (29) with the heels in the same position as the pusher plate arm.

44

Put in the intermediate cone (28).

45

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.

26 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put in the inner cone (27). Put the small recesses in the inner cone on the small heels on the pusher plate.

46

Put on the engaging ring (43) with the flat side up, the heels of the intermediate cone fit in the holes.

Note: The size of the engaging ring is 125.5 mm, see picture.

Assemble main shaft

47
Put shaft (46) in the press with the shaft end for the sun wheel upwards.

48

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
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27 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Place the needle bearing (47) and crawler gear (48) on the shaft, press on the hub (49).

Note: The machined part of the hub must be face downwards.

9996901
9996924

49

Put the engaging sleeve (50) on the hub, put the inner ring (51) for the reverse gear needle bearing on the shaft.

Note: The inner race must be placed so as to obtain an angle of 90° between the lubrication hole in the inner race and
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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28 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

the shaft.

50

Press on the inner race for the reverse gear needle bearing.

9996904

51
Place the needle bearing (52) and reverse gear (53) on the shaft.

52

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
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29 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Press on the bearing (54).

9996901

53

Press on the spacer ring (56).

9996901

54

Press on the sun wheel (57) with the large entry chamfer downwards.

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
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30 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

9996901

55
Turn the shaft over in the press.

56

Put the 2nd gear wheel (45) and needle bearing (44) on the shaft. Put on the complete synchronizing mechanism for
1st and 2nd gear with the recess in the engaging sleeve upwards.

Note: Take care that the synchronizing package does not fall apart.

57

Hold the synchronization still and turn the 2nd gear wheel (45) so that the engaging ring and cones drop into the
splines of the gear wheel.

Note: Make sure that the outer cone, pusher plate and recesses in the engaging sleeve are aligned.

58
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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31 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Press the guide sleeve to the bottom.

Note: Make sure that the outer cone, pusher plate and recesses in the engaging sleeve are aligned.

Special tools: 9996083, 9996725

59

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
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32 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Install the thickest possible retaining ring (25).

60

Put the 1st gear needle bearing (24) on the shaft, put on the 1st gear wheel (23), make sure the gear wheel goes into
the splines of the engaging ring.

61

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
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33 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put on the 3rd gear synchronising with the engaging ring upwards, make sure that the synchronization engages the
splines on the axle.

62

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
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34 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Press on the complete 3rd gear synchronization.

Special tools: 9996725

63

Press the P1 gear rear bearing (8) onto the shaft.

Special tools: 9992500

64

Put on the spacer ring (4). Put on the P1 wheel (7), make sure it engages the engaging ring.
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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35 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put on the front bearing (3). Press the bearing down onto the shaft.

Note: Max. press force 5 tons.

Note: If any of the bearing, spacer ring or gear wheel have to be changed, then all components must be changed
together.

Special tools: 9992500

65

Fit a new nut (2) and 9996480. Clamp the shaft in the press and torque tighten the nut to 400 ± 25 Nm.

Special tools: 9996480, 1159796

Specifications:
400±25 Nm

66

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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36 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Lock the nut with a cylindrical drift.

Note: The drift must have a rounded tip.

67

Press on the bearing (1) using 9992454.

Special tools: 9992454

68
Remove the shaft from the press and put it in a wooden fixture. Install synchronizing ring (6) and synchronizing cone
(5) for the splitter gear.

69

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
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37 / 38
IMPACT 4.00.51.00-SNAPSHOT 11/02/16

Put on the input shaft. Hold the engaging ring with both hands and make sure the engaging ring engages the 3rd gear
wheel.

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.

38 / 38