Assembly Transmission Volvo A40G
Assembly Transmission Volvo A40G
Transmission, assembling
Showing Selected Profile
Op nbr 421-067
Tools:
9993844 Regulator
9996239 Lifting chain
88800052 Fixture
88800055 Guide
11668020 Transport brace
11668020 Transport brace
11668020 Transport brace
E-1409 Connection
E-1668 Counterhold
E-2522
This operation also includes required tools and times for applicable parts of the following operations:
¡ Thread insert, changing and adjusting
¡ Reshimming
Support, installing
WARNING
Risk of frostbite! Use protective gloves.
1. Cool the support to a temperature not lower than -20 °C (-4 °F).
Figure 1
1. Support
Figure 2
1. Lock bolt for support
Figure 3
Figure 4
1. Thrust bearing
8. Install 88800052 Fixture that later is to be used for measuring axial clearance between support and rear cover.
NOTE!
Turn the tool so that the holder for the dial indicator faces out towards the control system. When the dial indicator is
installed, it should be possible to see it through the holes on the underside of the transmission housing.
Figure 5
1. 88800052 Fixture
2. E-1668 Counterhold
3. Holder for dial indicator
4. Inspection hole for dial indicator
Figure 6
1. Thrust bearing
Figure 7
Figure 8
14. Place the needle bearing on the sun gear, as shown in the figure above.
15. Install the brake discs for brake B2. The steel discs' tooth gap shall line up directly in front of the oil channel in the
transmission housing.
Start with a steel disc, then alternate between friction discs and steel discs. Finish with two steel discs.
NOTE!
When reinstalling existing discs, install these in the same order as they were installed before.
Figure 9
Figure 10
Figure 11
1. O–ring
18. Install both oil pipes, though the transmission housing and in to the brake piston.
Figure 12
1. Oil pipes
19. Install the lock ring that holds the brake piston.
NOTE!
The holes in the lock ring are tapered. To get a good grip with the pliers, the holes' small diameter should be turned to
face up.
NOTE!
Make sure that the lock ring is pushed well into the groove.
Figure 13
20. Check that the oil pipes are installed correctly by blowing compressed air in them. The brake piston should push out.
Figure 14
21. Check disc clearance for brake B2 with a feeler gauge. Measure between the two upper steel discs for brake B2.
For correct clearance, see Hydraulic transmission, specifications
NOTE!
If the clearance is not within specifications, adjust it with steel discs. For thickness of steel discs, see the Parts Catalog.
When adjusting disc clearance, the thickest steel disc shall be placed between both friction discs closest to the brake
piston.
Figure 15
22. Install planet stage 1 and the sun gear for planet stage 2.
Figure 16
1. Planet stage 1
2. Sun gear
23. Lubricate the needle bearing and thrust washer with vaseline.
Figure 17
24. Place the needle bearing and thrust washer on the sun gear for planet stage 2, as shown in figure.
Figure 18
1. Planet stage 2
2. Thrust washer
Figure 20
Figure 22
30. Install the lock pin for the thrust plate in the transmission housing, as shown in figure.
Figure 23
1. Lock pin
2. Brake discs
NOTE!
When reinstalling existing discs, install these in the same order as they were installed before.
33. Lay the thrust plate on the discs without pushing it into the groove. Turn the side with the smaller inner diameter so
that it faces down.
Figure 24
1. Thrust plate
34. Check the disc clearance for brake B3 with a feeler gauge. Measure between the thrust plate and the top edge of the
groove in which the thrust plate is to be installed.
Disc clearance, see Hydraulic transmission, specifications
NOTE!
If the disc clearance is not within specifications, adjust with steel discs. For thickness of steel discs, see the Parts Catalog.
Figure 25
1. Thrust plate
2. Lock pin
36. Install planet stage 3, use two C-clamps, sling, and an overhead crane for lifting.
Weight: approx. 15 kg (33 lb)
Figure 26
37. Check that the planet stage is in place by measuring the distance between the top of the gear teeth on the ring gear for
planet stage 4 and the thrust plate.
Distance: approx. 44 mm (1.732 in)
Check to find the cause if the measurement differs by more than one to two millimetres. (0.039 – 0,079 in)
Figure 27
38. Install the brake discs for B4. Begin with a friction disc, and then alternate between steel discs and friction discs.
Figure 28
Figure 29
1. Main shaft
2. Needle bearing
3. Thrust washer
43. Lube the thrust washer with vaseline and place it on planet stage 3.
If the old thrust washer is undamaged it can be used again. If it is worn, choose a new washer of the next thicker size.
The thickness of the thrust washer between planet stage 3 and 4 may vary between individual transmissions of the
same type, since adjustment of axial clearance in the transmission is done by choosing a thicker or thinner thrust
washer. For thickness of available thrust washers, see the Parts Catalog.
46. Install planet stage 4. Use 2 pcs. lifting eyes M8, lifting sling, and overhead crane.
Weight: approx. 20 kg (44 lb)
Figure 32
47. Measure the distance between the piston housing's gasket and the brake discs (h1).
Note the measurement (h1).
Figure 33
48. Place the piston housing on a table with the piston facing up.
Measure the distance between the piston and the housing's contact face (h2).
Note the measurement (h2).
Figure 34
49. The disc clearance is equal to the difference between the measurements, that is:
Disc clearance brake B4 = h1 – h2
Permitted disc clearance, see Hydraulic transmission, specifications
NOTE!
If the clearance is not within specifications, adjust it with thinner or thicker steel discs. For thickness of steel discs, see
the Parts Catalog.
50. Install the piston housing so that the oil channels in the piston housing and transmission housing line up directly
opposite each other. Use E-2510 Clamping tool and 9996239 Lifting chain for lifting.
Figure 35
52. Lubricate the thrust washer with vaseline and fasten on the underside of planet stage 5.
Figure 36
53. Clamp down a lifting sling between the washer that locks the drive flange and the output shaft, and install the
assembled shaft, clutch, and planet stage in the transmission.
Figure 37
54. Lube the piston rings on the output shaft with vaseline and centre them around the shaft to avoid damaging them
when the rear cover is installed.
Figure 38
1. Ring
2. Piston rings
Ring, installing
55. Install the ring so that the oil channels in the ring and piston housing line up directly opposite each other.
56. Install a new gasket between the ring and the cover.
NOTE!
Make sure that the holes for the oil channels are not blocked by the gasket.
57. Install the discs for B5 with the steel discs' gear tooth gap down towards the sump, as shown in the figure. Begin with a
steel disc, then alternate between friction discs and steel discs.
Figure 39
1. Gasket
2. Tooth gap
58. Fasten a steel ruler on top of the ring using two long bolts from the rear cover.
Measure the distance (h1) from the ruler's top edge to the brake disc.
Note the measurement (h1).
Figure 40
59. Measure the distance (h2) from the ruler's top edge to the gasket.
Note the measurement (h2).
Subtract the measurement (h2) from the measurement (h1), that is, (h1) – (h2) = (h3)
Add the fixed value 5 mm ( 0.197 in) to the measurement (h3). The fixed value represents the rear cover's clearance.
Disc clearance, brake B5 = (h3) + 5 mm ( 0.197 in)
Disc clearance B5, see Hydraulic transmission, specifications
NOTE!
If the clearance is not within specifications, adjust it with thinner or thicker steel discs. For thickness of steel discs, see
the Parts Catalog.
Figure 41
60. Lube with plenty of vaseline on the bevelled edge on the rear cover's inside to protect the piston rings on the output
shaft when installing.
Figure 42
1. Lube with plenty of vaseline on the bevelled edge on the rear cover's inside
61. Install E–2522 Press tool on the rear cover. Install lifting eyes M10 in the E-tool's nuts, then connect lifting sling and
lifting device.
Figure 43
63. Place the drive flange and washer on the output shaft and drive them down so far that the washer's bolts enter the
threads in the output shaft.
NOTE!
Make sure that the gasket's inner radius between the ring and cover is not damaged by the cover's flange.
Figure 44
64. Torque-tighten the washer. Use two bolts and a pry bar as counterhold when tightening.
Tightening torque, se: Hydraulic transmission, tightening torque
Figure 45
65. Install the bolts for the rear cover. Tighten the bolts crosswise in two sequences.
NOTE!
Do not forget to install and angle the plate for the cable harness, as shown in the figure.
Figure 46
1. Plate
Axial clearance between support and rear cover, checking
67. Tap on the drive flange to lay the planet stages in place.
Figure 47
Figure 48
1. Dial indicator
69. Rotate the transmission half a turn. Push, pull, and turn the drive flange to lay the planet stages in place.
1. Dial indicator
71. Rotate the transmission back and forth a few times and repeat measuring of the axial clearance.
Compare the highest measured axial clearance with specifications.
Axial clearance: see Hydraulic transmission, specifications
If the axial clearance is within permitted limits, assembly continues after the section Axial clearance between support and
rear cover in transmission, adjusting.
Figure 50
73. Install brake discs for brake B1 in the transmission housing. Begin with a steel disc. Then alternate between friction discs
and steel discs.
Figure 51
74. Install the brake piston for brake B1 in the transmission housing.
NOTE!
Make sure that the hole in the brake piston for the oil pipe lines up with the matching hole in the transmission housing.
Figure 52
1. O–ring
76. Install the oil pipe through the transmission housing in the brake piston. Use a bolt M12.
Figure 54
77. Install the lock ring for the brake piston. Turn the lock ring's opening so that it faces the bracket for the turbine rpm
sensor, SE4213.
NOTE!
Make sure that the lock ring enters well into the groove.
Figure 55
78. Check the disc clearance for brake B1 with a feeler gauge. Measure between the top brake disc and the brake piston.
Permitted disc clearance, see Hydraulic transmission, specifications
NOTE!
If the disc clearance is not within specifications, adjust the clearance by changing one or several steel discs to a thicker
or thinner disc. For disc thickness, see the Parts Catalog.
Figure 56
79. Connect E-tool E-1409 Connection to the oil channel for brake B1.
Figure 57
E-1409 Connection
80. Pressurise brake B1 with a pressure of approx. 0.2 MPa (2 bar) (29 PSI). Use 9993844 Regulator to control the air
pressure.
Figure 58
1. 88800052 Fixture
82. Install clutch K2. Use E-1636 Lifting tool for lifting. Secure the lifting tool with a tensioning strap or similar.
Weight, clutch K2: approx. 14 kg (31 lb)
Figure 60
83. Remove E-1636 Lifting tool and the tensioning strap from the clutch.
84. Align the clutch discs with tool 88800055 Guide in clutch K2, if this is not already done.
Figure 61
87. Pressurise clutch K2, by connecting compressed air to E-1409 Connection, and then applying a pressure of approx. 0.2
MPa (2 bar) (29 PSI). Use 9993844 Regulator to control the air pressure.
NOTE!
Counterhold the tool with one hand when the clutch is pressurized to prevent the tool from moving out of position.
Should this happen, the tool has to be removed to check that the piston rings on the support are centred and
undamaged.
Figure 62
1. 88800055 Guide
89. Place the thrust washers and needle bearing on clutch 2 as shown in figure. Lube these with vaseline before they are
installed.
Figure 64
90. Fasten a lifting sling around the turbine shaft on clutch K1.
Figure 65
91. Lift clutch K1 and lower it carefully so that the discs in clutch K2 are not moved out of position.
Weight, clutch K1: approx. 21 kg (46 lb)
92. Measure the distance between brake piston B1 and the top side of clutch K2 to make sure that the clutch is in the
correct position. The distance between B1 and K2 should be approx. 61 mm (2.402 in).
Figure 66
95. Insert the cable harness for the control system through the hole where connector (EH) is to be installed.
Figure 68
96. Insert the cables for the control system's PWM-valves through the hole to the control system.
Figure 69
1. Cable harness for control system, SE4212 and SE4213, entry point
2. Cable harness for control system, exit point
3. Cable harness for SE4212, exit point
4. Cable harness for SE4212, entry point
5. Turbine speed sensor, SE4213
97. Insert the cable for sensor SE4212 through the hole beside and up through the hole in the flange on the transmission
housing. The lock ring for B1 may have to be moved aside to enable the connector to pass through the hole in the
housing.
98. Press down the cable harness in the groove in the transmission housing.
99. Install the turbine speed senor, SE4213, in the bracket on the brake piston. Tighten the sensor.
Tightening torque, see: Hydraulic transmission, tightening torque
Figure 70
1. Connector (EH)
101. Install the cable harness for SE4212 input speed (rpm) in the transmission housing with a clamp.
Figure 71
1. Position of clamp for cable harness for SE4212 input speed (rpm)
Figure 72
1. Stator shaft
2. Guide pins, M12x200
3. Gasket
105. Using the guide pins, install the torque converter housing on the transmission housing. At the same time, insert the
cable for the input speed sensor SE4212 through the hole in the torque converter housing.
Weight, torque converter housing: approx. 31 kg (68 lb)
Figure 73
106. Install a guide pin M10x100 in the torque converter housing and fit it into the stator shaft on the torque converter
housing's underside.
Figure 74
Figure 75
1. Oil pump
2. Guide pin
108. Install new bolts and washers for the torque converter housing, the oil pump, and retarder.
Figure 76
M10x80
M12x80
1 Sensor for input speed SE4212.
2 Clamp
3 Drive sleeve
109. Tighten all bolts crosswise, from the inside and out.
Tightening torque, see: Hydraulic transmission, tightening torque
110. Check that the pump does not bind by manually rotating the drive sleeve. It must be possible to rotate the drive sleeve
without using major force.
112. Lube the O–ring bevel in the torque converter housing with vaseline.
Figure 77
113. Place the seal shield loosely in the torque converter housing, install the bolts with new seals.
Figure 78
114. In stages, tighten down the seal shield in the torque converter housing with the bolts.
Tightening torque: Hydraulic transmission, tightening torque
115. Lubricate the piston ring in the end of the turbine shaft with vaseline.
Figure 79
116. Install two lifting eyes (M12) on the torque converter. Use the eyes, shackle, lifting sling, and overhead crane to lift
down the torque converter in the housing.
Figure 80
1. Lifting eyes, M12
2. Piston ring on torque converter's bushing
3. Piston ring on turbine shaft
117. Make sure that the piston ring located on the outside of the torque converter's drive sleeve is lubed with vaseline.
118. Check that the torque converter is in the correct position by using 11668020 Transport brace as reference. The distance
between the top of the torque converter and the retainer plate's underside should be approx. 5 mm (0.2 in)
Figure 81
120. Install three 11668020 Transport brace between the torque converter and torque converter housing:
1. Begin by installing and tightening the bolts that hold the retainer plates to the torque converter housing.
2. Then install and tighten the bolts that hold the torque converter to the retainer plates.
1. Cover
122. Install the cover together with a new gasket. Torque-tighten the bolts crosswise, from the middle of the cover and
outward.
Tightening torque, see: Hydraulic transmission, tightening torque
123. Install the filter holder for the main pressure filter in a vice and remove the plug for the relief valve (overflow valve).
NOTE!
There are two pretensioned springs behind the plug.
Figure 83
124. Check the springs and the peg. Replace damaged parts.
Figure 84
125. Install the peg and the springs in the main pressure valve. Change O–ring on the plug and install it.
Tightening torque: Hydraulic transmission, tightening torque.
126. Install the filter holder for the main pressure filter with a new gasket on the transmission housing.
NOTE!
After test-running the transmission, check-tighten the bolts.
Figure 85
127. Press down the cable harness in the moulded groove in the transmission housing.
Figure 86
1. Plate
129. Install all bolts for the control system together with the temperature and level sensor, SE4202/SE4203, suction strainer,
clamps, and PWM-valves, see figure below.
NOTE!
Check which bolts should be installed together with a clamp.
NOTE!
Check the marking on the PWM-valves on the control system and the marking on the connectors on the cable harness,
so that the correct connector is plugged into the correct PWM-valve.
NOTE!
Last, install the suction strainer.
130. Check-measure the PWM-valves in the transmission, see PWM4205-PWM4212, description and measuring. Plug in the
measuring equipment to connector EH (Canon connector).
131. Install two guide pins, M8x85 mm, on the transmission housing where the oil sump is to be installed.
Figure 88
1. Guide pins
2. Gasket
Figure 89
135. Install the bolts that hold the oil sump. Replace the guide pins with bolts.
138. Change O-rings on all sensors, plugs, and pressure check connections. Install the sensors, plugs, and pressure check
connections.
For positions and tightening torques, see Transmission, component location and Hydraulic transmission, tightening
torque
139. Secure the transmission by attaching an overhead crane in the eye on 9998169 Fixture.
Figure 91
1. Overhead crane
2. 9998169 Fixture
142. Change O-rings on the oil pipes and lube them with vaseline.
Figure 92
143. Install the oil pipe for filling oil in the transmission housing.
NOTE!
Do not tighten the bolt for the connector's bracket, leave the bracket loose. This is for easier installation of the
transmission in the machine.
145. Place plastic bags around the filter holders and fasten them with cable ties.
Figure 93