05:03-02

Issue 1 en

Gearbox GRS900

Work description

 Scania CV AB 1995-10
1 585 768 Mechanic Development
Digitally signed by Mechanic
Development
DN: cn=Mechanic Development,
o=PT.Pamapersada Nusantara,
ou=Instractor-159, c=ID
Signature Not Verified Date: 2005.05.22 08:31:30 Z
Contents

Contents
Gearbox Dismantling ........................................................ 5

Input shaft Dismantling ...................................................... 15

Assembly ......................................................... 18

Mainshaft Dismantling ...................................................... 21

Replacement of bearing races
in high-split gearwheel .................................... 23
Assembly ......................................................... 24

Lay shaft Dismantling ...................................................... 31

Assembly ......................................................... 33

Synchromesh Dismantling ...................................................... 35

Checking .......................................................... 36
Assembly ......................................................... 40

Gearshift housing, Dismantling ...................................................... 41

manual gearbox Assembly ......................................................... 45

Gearshift housing, Opticruise Hall effect sensors ............................................ 49

Longitudinal stroke cylinder ............................ 51
Lateral stroke cylinder ..................................... 52

Gear selector housing Dismantling ...................................................... 53

Assembly ......................................................... 55

Gearbox Assembly ......................................................... 57

Setting bearing clearance ................................. 67
Fitting the planetary unit .................................. 69
Fitting gear selector housing
and gearshift housing ....................................... 75

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 Contents

Wiring diagram and pneumatic .......................................................................... 79

circuit diagram

Specifications .......................................................................... 80

Fitting parts .......................................................................... 82

Special tools .......................................................................... 83

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Gearbox

1 2 3 4

5 6 7

05_5636

1 Input shaft
2 Gearshift housing
3 Mainshaft
4 Gear selector housing
5 Oil pump
6 Lay shaft
7 Reverse gear shaft

GRS900, main components

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 Gearbox

Gearbox
Dismantling

Special tools

Number Designation

79 046 Drift
87 758 Drift
98 765 Splined socket
99 074 Impact drift
99 154 Support drift
99 167 Lifting tool
99 193 Lifting tool
99 198 Fixture

Other tools

587 511 Puller

587 585 Retaining ring pliers

1 Remove wiring, air hoses, solenoid valve

(splitter interlock) and the air cylinder for
the splitter gear.

Remove the gearshift housing, the cover

behind the gearshift housing and the three
springs and plungers.

2 Fit lifting tool 99 193 with two M10 nuts

using two M14 nuts as spacers and two
M10 X 25.

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Gearbox

3 Remove power take-off/cover for power

take-off.

05_5565
4 Fit fixture 99 198.

5 Fit the gearbox in the universal stand.

6 Remove the cover retaining bolts. Lift the
gear selector housing with selector forks.
Remove lifting tool 99 193.

7 Turn the gearbox 90˚ in the stand, with the

planetary part up.

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 Gearbox

For removing planetary gear with retarder, see

booklet entitled ”Planetary gear, Gearboxes
GR/GRH/GRS/GRSH900”
8 Loosen, but do not remove, the round nut
for the end yoke.

9 Undo and turn the shift cylinder on the

right-hand side in order to gain access to the
retaining bolts.

10 Remove the 13 retaining bolts. Remove the

three guide pin lock bolts.

11 Remove the guide pins using impact drift

99 074.

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Gearbox

12 Fit lifting tool 99 167 to the end yoke. Lift

out the planetary gear and place it to one
side.
Reconditioning the planetary gear, see booklet
entitled ”Planetary gear, Gearboxes
GR/GRH/GRS/GRSH900”.

13 Remove the round nut. Use splined socket

98 765 for the standard planetary gear. Use
socket 587 586 for the planetary gear with
Scania retarder and/or 2 circuit control.

14 Remove the oil nozzle (8 mm internal hexa-

gon). (Not necessary if the mainshaft is not
being changed).
Note: Do not use a nut runner. Heat the locking
compound as necessary instead.

15 Fit support drift 99 154 or 98 575 if the oil

nozzle is still in place in the end of the shaft.
Withdraw the synchromesh cone and sun
wheel using puller 587 511.

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 Gearbox

16 Remove the shim(s) and spacing ring.

17 Remove the mainshaft retaining ring using

pliers 587 585. Remove the shims.

18 Rotate the gearbox through 180˚.

Note: The bearing race for the mainshaft may
drop out.
19 Detach both connections from both pipes
inside the clutch housing. Pull off the unions
and detach the pipes.
20 Plug both slave cylinder connections in
order to prevent dirt getting into the hydrau-
lic part.

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Gearbox

21 Remove the four slave cylinder retaining

bolts.

22 Remove the slave cylinder and V-ring seal.

23 Remove the eight clutch housing bolts.

Remove the clutch housing.

24 Remove the oil filter and overflow valve

(also called dump valve) beside the oil filter.

In trucks with oil cooling, the spacer should

also be removed.

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 Gearbox

25 Remove the oil pump.

26 Withdraw the input shaft and its bearing

outer race.

27 Shake the mainshaft and collect the outer

race.

28 Remove the two oil pipe securing bolts.

Remove the oil pipe. Remove the spacing
sleeve at the front edge and remove the
O-ring inside the sleeve.

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Gearbox

29 Rotate the gearbox almost 90˚ to prevent the

front synchromesh assembly from falling
out.
30 Fit a lifting strap round the mainshaft.
31 Mark the latch cone with a marker pen or
similar. Lift up the mainshaft sufficiently far
for the synchromesh and latch cones for low
split to be removed. Lift slightly further and
remove the synchromesh for the splitter
gear. Hold the synchromesh together and
place it to one side.
32 Lift out the mainshaft. Lowering the front of
the gearbox slightly will facilitate this.

33 Remove the lock bolt for the reverse gear

shaft and drive the shaft out to the rear. Use
drift 79 046.

34 Lift out the washer, needle bearings and

spacer.

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 Gearbox

35 Fit the lifting strap round the lay shaft.

Remove the retaining ring and shims. Use
pliers 587 585.
36 Push the shaft to the rear and remove the
bearing race.

37 Lift out the shaft.

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Gearbox

38 Remove the O-ring in the bearing seat for

the rear bearing.

Remove the oil strainer and clamp, spacing

sleeve and O-ring.

39 Drive out the lay shaft’s front bearing outer

races, using drift 87 758.
40 Wash and blow dry the housing and oil-
ways.

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 Input shaft

Input shaft

Dismantling

Special tools

Number Designation

87 596 Impact drift

99 136 Hollow drift
99 141 Support ring

Other tools

587 312 Retaining ring pliers

1 Remove the spacing ring and the two piston

rings by hand.

2 Remove the retaining ring. Use retaining

ring pliers 587 312.

The bearing inner race may have to be

tapped down slightly first, using a drift and
hammer.

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Input shaft

3 Place the shaft on hollow drift 99 136 and

support ring 99 141. Press out the bearing
and gearwheel.

4 Remove the bearing and gearwheel.

Remove the bearing halves.

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 Input shaft

5 Cut a screw thread in the oil pipe using an

M10 pilot tap.

6 Withdraw the oil tube by means of an M10

bolt with welded-on washer and impact drift
87 596. Clean the oilway.

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Input shaft

Assembly

Special tools

Number Designation

98 224 Press plate

98 334 Drift
98 450 Shank
98 636 Drift
99 136 Hollow drift
99 141 Support ring

Other tools

587 312 Retaining ring pliers

05_5635
Input shaft

1 Place the shaft in press plate 98 224.

2 Press in the oil tube with shank 98 450.

Press the tube in so that it protrudes
21.5 mm or more (dimension A).

Check that the lubricating holes are free.

The tube must not be clinched.

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 Input shaft

3 Turn the shaft around.

4 Lubricate and fit the bearing halves.

5 Fit the gear, splines downward.

6 Press on the bearing with drifts 98 334 and

98 636.

7 Fit the retaining ring using retaining ring

pliers 587 312. Select a retaining ring so that
the minimum possible clearance is obtained
between ring and bearing.

Make sure that the retaining ring enters the

groove.

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Input shaft

8 Place the shaft on hollow drift 99 136 and

support ring 99 141. Press the bearing
against the retaining ring with a maximum
force of 70 kN (7 tonnes).

9 Fit the two piston rings and the spacing ring

between them.

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 Mainshaft

Mainshaft

Dismantling

Special tools

Number Designation

87 237 Support drift

98 322 Lifting tool
98 575 Drift
99 136 Hollow drift
99 140 Support ring
99 154 Support drift

Other tools

587 318 Extractor plate

587 319 Puller
587 600 Socket

On dismantling the mainshaft, the synchromesh

components should be identified with marking
paint. This is to ensure that the latch cone, driver
and sleeve will be refitted in the same positions
as before, i.e. the sleeve and driver must not be
moved in the splined joint. The latch cone lugs
should fit in the same recesses as they did from
the beginning.

1 Pull off the front bearing.

Use support drift 87 237, extractor plate

587 318 and puller 587 319.

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Mainshaft

2 Remove the round nut using socket

587 600.

3 Attach lifting tool 98 322 and lift the shaft

over to the press.

4 Insert the shaft in hollow drift 99 136, being

careful to centre it. Place rubber sheeting or
the like in the drift to damp the impact when
the shaft is lowered.
5 Press out the rear bearing, the reverse gear-
wheel, crawler and 1st gear gearwheels.
Protect the end of the shaft using support
drift 99 154 or 98 575 if the oil nozzle has
not been removed.

Remove the gearwheel, synchromesh and

bearing. Hold together the synchromesh as
one unit. Mark the parts and place the syn-
chromesh unit to one side.

6 Reverse the shaft and insert it in hollow drift

99 136. Use support ring 99 140. Protect the
end of the shaft with support drift 98 575.
7 Press out the shaft. Remove the second-gear
and high-splitter gearwheels with associated
synchromesh assemblies. Mark the splitter
gear to be sure that it faces in the same
direction on reassembly. Keep the synchro-
mesh assembly together as a single unit.
Mark the parts and place the assembly to
one side.

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 Mainshaft

Changing bearing races for

high-split gearwheel

Special tools

Number Designation

87 446 Drift
87 758 Drift

Other tools

587 316 Holder

587 530 Puller

1 Use puller 587 530 and holder 587 316 to

extract one of the bearing races. Use spacers
of e.g. sheet aluminium.

2 Press out the other bearing race using drift

87 758.

3 Press in new bearing races using drift

87 446.

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Mainshaft

Assembly

Special tools

Number Designation

87 089 Drift
87 550 Drift
87 932 Drift
88 292 Shank
98 075 Dial gauge
99 127 Drift
99 136 Hollow drift
99 190 Drift
99 191 Drift
99 199 Holder
99 201 Support ring

Other tools

05_5433
587 250 Magnetic foot
587 600 Socket Mainshaft

1 Fit the needle bearing.

2 Fit the second-gear gearwheel with the

splined flange upwards.

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 Mainshaft

3 Fit the synchromesh assembly for sec-

ond/third gear with the driver’s longer neck
downwards. Guide it onto the splines and
press if necessary.

4 Press on one of the splitter gearwheel bear-

ings.

5 Fit the spacing ring first and then the shims.

When measuring the clearance, start with
too large a clearance. Accordingly, fit one
shim more than before.

6 Fit the high-split gearwheel. Align it in the

splines on the synchromesh assembly’s syn-
chromesh cone.

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Mainshaft

7 Press on the other bearing, using drifts

99 190 and 99 191. Rotate the gearwheel
while pressing it. Stop pressing if the gear-
wheel does not rotate easily and change to a
thicker shim. See point 11.

8 Fit the round nut. Use holder 99 199, shank

88 292 and socket 587 600.

Tightening torque 400 Nm.

9 Check the clearance for the high-split gear-

wheel. Stand the shaft on holder 99 199 or
clamp it in a press at a pressure of
10 - 20 kN. Fit dial gauge 98 075 and mag-
netic foot 587 250.
10 Rotate the gear a few turns, always in the
same direction. Prise the gear upwards,
using two screwdrivers. Rotate the gear and
measure the clearance at least three times.
Mark the gear so that the clearance is
always measured at the same place. Calcu-
late the average. Correct clearance:
0.03 - 0.06 mm.

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 Mainshaft

11 Adjusting clearance:

Remove the round nut. Press up the shift

sleeve to gear position 3. Set the shaft in
hollow drift 99 136 with support rings
99 201 and press out the bearing.

Fit new shims and start again from point 6.

12 When the correct clearance has been

achieved, undo the nut. Secure with locking
compound 561 200 and tighten.

Tightening torque 400 Nm.

13 Clinch the nut and remove holder 99 199.

The front bearing can be pressed on at this

point, see point 21, but great care must be
taken when the shaft is turned and other
inner races are being pressed on.

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Mainshaft

14 Reverse the mainshaft.

Use drift 98 568 as a support under the shaft

if the front bearing has been fitted.
15 Lubricate and fit the needle bearing and
first-gear gearwheel, splines upwards, on
the shaft.

16 Align the synchromesh disc in the gear-

wheel splines. Fit the retaining ring. Insert
the pins in the synchromesh disc. Fit the
inner cone. Align the middle cone with the
pins and fit it.
Fit the latch cone.

Finally, align the driver plate with the inner

cone and latch cone. Lubricate the splines
and thread the driver on, with the long neck
up, pressing if necessary. Align the latch
cone with the recesses in the driver.

17 Lubricate and press on the inner race for the

needle bearing of the crawler gearwheel.
Use drifts 87 550 and 99 127. Fit the needle
bearing.

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 Mainshaft

18 Fit the crawler gearwheel, synchromesh

tooth upwards. Fit the driver, by means of a
press if necessary, using drifts 87 550 and
99 127.

19 Fit the shift sleeve.

20 Lubricate and press on the inner race for the

reverse gear’s needle bearing.

Use drifts 87 932 and 99 127.

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Mainshaft

21 Fit the reverse gear needle bearing and gear-

wheel, synchromesh tooth downwards.

22 Lubricate the rear bearing and press it on

using drift 87 932.

23 Reverse the shaft and press on the front

bearing using drift 87 089.

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 Lay shaft

Lay shaft

Dismantling

Special tools

Number Designation

98 575 Drift
98 647 Support drift
99 136 Hollow drift
99 140 Support ring
99 142 Support ring
99 143 Split support ring

Other tools

587 312 Retaining ring pliers

587 318 Extractor plate
587 319 Puller

1 Pull off the rear bearing using extractor

plate 587 318 and puller 587 319.

Use support drift 98 647.

If the bearing breaks, split it.

2 Pull off the front bearing using extractor

plate 587 318 and puller 587 319. Use sup-
port drift 98 647. Loosen the bearing
slightly first and then grip again.

If the bearing breaks, split it.

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Lay shaft

3 Remove the retaining ring. Use retaining

ring pliers 587 312.

4 Place the lay shaft in a press and press off its

low-split gearwheel. Use hollow drift
99 136 with split support ring 99 143 and
drift 98 575. Place rubber sheeting or the
like in the hollow drift to damp the impact
when the shaft drops down.

5 Press off the high-split gearwheel. Use hol-

low drift 99 136 with support ring 99 140.
Remove the spacing ring.

6 Press off the second-gear gearwheel. Use

hollow drift 99 136, support ring 99 142 and
drift 98 575.

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 Lay shaft

Assembly
Special tools

Number Designation

98 638 Drift
99 136 Hollow drift
99 142 Support ring
99 190 Drift
99 191 Drift
98 575 Support drift

All three gears are bonded to the lay shaft.

Before the gears are bonded to the shaft the sur-
faces must be washed thoroughly with a degrea-
sing solvent. Then apply locking compound
584 075 (Loctite 16 705) evenly on both sur-
faces to ensure good adhesion.

05_5545
Note: If the right locking compound is not used
the correct press force will not be achieved. This Lay shaft
could result in the wheels rotating on the lay
shaft.

To ensure the strength of the joint, the press

force employed in connection with mounting
must be at least 300 kN (30 tonnes) just before
the gears bottom.

1 Place the shaft on support ring 99 142 and

press on the second-gear gearwheel. Protect
the end of the shaft with support drift
98 575.
Note: The press force must be at least 300 kN
(30 tonnes).

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Lay shaft

2 Fit the spacing ring. Press the high-splitter

gearwheel on the shaft. Protect the end of
the shaft with support drift 98 575.
Note: The press force must be at least 300 kN
(30 tonnes).

3 Press the low-splitter gearwheel on the

shaft.
Note: The press force must be at least 300 kN
(30 tonnes).

4 Press on the rear bearing using drift 99 190

and drift 99 191.

5 Turn the shaft around in the press.

6 Fit the retaining ring. Place the shaft on drift
99 191.
7 Press on the front bearing using drift
98 638.

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 Synchromesh

Synchromesh

Dismantling
Mark the parts of the synchromesh mechanism
with a marking pen. All the parts are assembled
loosely and no special tools are required to dis-
mantle or assemble them.
Note: Keep the various parts of each synchro-
mesh assembly separate from the parts of other
synchromesh assemblies.

1 Synchromesh cone
2 Latch cone
3 Driver
4 Compression spring
5 Plunger
6 Cylindrical roller
7 Shift sleeve

Low and high splitter gear synchromesh

Second and third gear synchromesh

1 Synchromesh disc
2 Pin
3 Retaining ring
4 Inner cone
5 Middle cone
6 Latch cone
7 Driver plate
8 Driver
9 Compression spring
10 Plunger
11 Cylindrical roller First-gear synchromesh
12 Washer
13 Shift sleeve
14 Retaining ring

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Synchromesh

Checking
1 Check the wear to the cones by placing the min 0.5
synchromesh cone with its cone up on a flat
surface and then placing the latch cone on
top.

Make sure that the latch cone is properly

aligned with the synchromesh cone and
press it on by hand. Measure the gap
between the cones using a feeler gauge.
Minimum permitted clearance is 0.5 mm.
Look at the wear pattern on the cones and
check that the cone surfaces are correct.

05_5525
Min. air gap = 0.5 mm
Air gap, new sync = 1.1 0.3 mm
Third/second gear, low-splitter gear and high-
splitter gear synchromesh

For first gear synchromesh, the following

check procedure applies: min 0.5 min 0.7

Lift out the inner cone, middle cone and

latch cone and place them on support ring
99 139. Centre the synchromesh parts so
that the latch cone is loaded.
Using a steel rule and feeler gauge, measure
as illustrated. For greater accuracy, measure
twice at opposite points and calculate the
average. If the minimum dimension is not 99 139
achieved, faulty part(s) should be changed.
05_5169

99 139

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 Synchromesh

2 Check the synchromesh sleeves, looking at

their teeth. The tooth latch flanks should be
pointed with a wedge shaped ”flat surface” E
at the tip and there should be no burr (see
illustration). D

A certain degree of rounding of the tip A

05_5438
can be permitted as this does not signifi- C
cantly impair function. Only a small amount
of rounding of the edge between latch flank B A
B and locking flank D is permitted. A great
deal of wear here, C, can cause the gear to Latch tooth in sleeve
jump out under load.
A= Plate
Check that the locking flanks D are free of
burr and that there is a clear edge to locking B = Latch flank
flank E. Asymmetrical flanks B are not per- C= Edge
mitted.
D = Locking flank
E = Termination of locking flank

3 Check that the edges of the latch cone teeth

are not round. Check that the cone oil drain
thread is intact throughout the entire cir-
cumference.

The coating inside the cone must not be

lacking in any part of the circumference.
However, slight chipping at the edge is per-
mitted (maximum 2 mm from the edge).

Place the driver on a flat surface and place

the latch cone on top as marked earlier.
Finally, fit the synchromesh cone and check
that the latch cone can move freely when the
synchromesh cone is pressed against the
driver.

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Synchromesh

4 Check the synchromesh cone teeth. The

teeth latch flanks should be pointed, with a
”flat surface” at the tip and there should be D
no burr.

05_5439
C
Only a small amount of rounding of the
edge between latch flank B and locking
B A
flank D is permitted. A large amount of
wear, C, can cause the gear to jump out
under load. Check that the locking flanks D
are not burred. Latch tooth on synchromesh cone

The cone surface should be flat with no A= Plate

unevenness which can be felt with the B = Latch flank
thumb nail, e.g. from the latch cone thread.
There may sometimes be brown burn marks C= Edge
on the surface. These do not affect function D = Locking flank
provided that they cannot be felt with the
thumb nail.

5 The same checking procedure as above also

applies to first-gear synchromesh. The dif-
ference is that the surface of the cones has to
some extent changed place. For instance,
the latch cone has a ground surface and the
middle cone, which is not incorporated in a
single synchromesh mechanism, has two
coated surfaces with draining threads.

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 Synchromesh

1 Inspect the first-gear synchromesh driver

plate for cracks. The width of the lugs must
not be less than 18.5 and 8.0 mm, see adja-
cent figure.
2 Check that the washer (12 s 35) is securely
mounted on the first-gear driver and that its
four metal tongues holding the roller in
place are not bent.

1. Possible crack formation

8 Check that there are no scoring marks on the

drivers’ end planes against each gearwheel.
9 Assemble the driver and sleeve as marked
earlier. Check that each shift sleeve moves
easily on the drivers. A binding sleeve can
cause problems with heavy gear changing.
Approved radial clearance between the
driver and shift sleeve is min. 0.2 mm.

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Synchromesh

Assembly
Assemble the synchromesh assemblies in
accordance with the marks made earlier. Insert
the driver’s four plungers and compression
springs in their respective holes. Fit the shift
sleeve. Insert the cylindrical rollers using a
screwdriver or the like.
Note: A sleeve with one groove is always
placed on double synchromesh assemblies with
the groove facing the double synchromesh
assembly. On sleeves with two grooves or no
grooves at all, the toothed edge should face for-
wards.
The synchromesh assembly for the low-split and Groove/angle 50˚ Groove, if present.
high-split gearwheels should not be assembled With no groove, tip
until it is fitted on the mainshaft. angle is 58˚

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 Gearshift housing

Gearshift housing

Dismantling

Special tools

Number Designation

87 474 Drift
98 289 Drift
98 450 Shank
99 053 Drift

1 Remove the unions from the neutral posi-

tion valve and then the valve itself.

2 Remove the reverse gear switch. Shake out

the plunger.

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Gearshift housing

3 Remove the venting cover.

4 Remove the coulisse. The bolts may be

secured with locking compound. Heat as
necessary.

5 Slacken the inner lever and move it on the

shaft.

6 Remove the key.

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 Gearshift housing

7 Detach the rubber boot.

Remove the shaft and inner lever.

8 Remove the retaining ring and remove the

venting filter and stroke spring.

9 Remove the seal using a screwdriver

10 Press out the bearing bushing with bushing

sleeve and needle bearing. Use drift 99 053
and shank 98 450.

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Gearshift housing

11 Press out the other needle bearing.

12 Press out the bushing from its steel sleeve

using drift 87 474. Use drift 98 289 as a
holder.

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 Gearshift housing

Assembly

Special tools
Number Designation
87 362 Drift
87 474 Drift
98 450 Shank
98 289 Drift
99 053 Drift

1 Positioning of bearings
2 Positioning of bearing bushing

1 Press a new bushing into the bushing sleeve

using drift 87 474. Use drift 98 289 as a
holder.

The bushing should be centered in its

sleeve.

2 Press in one of the bushings using drift

99 053 and shank 98 450.

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Gearshift housing

3 Press in the needle bearing and the other

bearing bushing using drift 99 053 and
shank 98 450.

4 Press the seal in place using drift 87 362.

5 Fit the lateral stroke spring and venting fil-

ter.

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 Gearshift housing

6 Fit the retaining ring

7 Fit the shaft and inner lever

Fit the rubber boot

8 Fit the key.

9 Fit the lever bolt.

Tightening torque 92 Nm.

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Gearshift housing

10 Fit the coulisse. Lock the bolts using lock-

ing compound 561 200.

Tightening torque 25 Nm.

11 Fit the venting cover.

12 Fit the plunger and the reverse gear switch.

Tightening torque 25 Nm.

13 Fit the neutral position valve in place with a

new O-ring.
14 Fit the unions on the neutral position valve.

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 Opticruise

Opticruise

Hall effect sensor,

adjusting and changing
Use the integrated test program in the control
unit or Scania Diagnos to reveal faults in the hall
effect sensor and to verify that faults have been
corrected after repair has been carried out.

Removal
1 Set the driving mode selector to the neutral
position.
2 Detach the air hoses from the longitudinal
stroke cylinders and the lateral stroke cylin-
ders. Unplug the connector to the hall effect
sensor wiring from the sensor housing.
3 Remove the gearshift housing from the
gearbox and place it upside down on the
work bench.
4 Remove the sensor housing from the gear-
shift housing.
5 Using compressed air, blow into the centre
air connection on the longitudinal stroke
cylinder. This sets the gear selector shaft to
neutral. Check that the lever lug is centered
in the coulisse as illustrated to the right.

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Opticruise

Checking and adjusting

6 Remove both the guide pins from guide
plate 99 150 (these are not necessary). Fit
the guide plate in the place of the sensor
housing. Check that the magnet housing is
in the correct position.
7 When adjusting: Undo the magnet housing
bolts sufficiently far to make it possible to
move the magnet housing, but no further. 4 1

Note: The bolts are locked with locking com-

pound, but do not heat the magnet housing. This
may damage the magnet. 2
3
8 Adjust the position of the magnet housing
using the guide plate. Then lock the bolts
with locking compound 561 200 and screw
then fully down.

05_5174
3

1 Sensor housing
2 Magnet housing
3 Spring pins
4 Guide plate 99 150
Figure shows 3-series design

Hall effect sensor, fitting

9 Fit the sensor housing to the gearshift hous-
ing. Refit the gearshift housing to the gear-
box.

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 Opticruise

Changing the longitudinal

stroke cylinder
The vehicle’s compressed air system must be
pressurized for the longitudinal stroke cylinder
to be set to the correct position before it is
removed.
1 Switch on the power. Set the driving mode
selector to neutral. This sets the longitudinal
stroke cylinder to neutral.
2 Cut the power. Disconnect the three air
hoses from the longitudinal stroke cylinder.
3 Undo the four fastening bolts and remove
the cylinder.
4 Fit the new cylinder. Blow compressed air
into the centre connection, setting the cylin-
der to the neutral position. Make sure that
teeth on the gear shift shaft are engaged in
the centre position.

05_5336
5 Fit the air hoses.
6 Remove the level plug. Fill with ATF fluid
up to the hole (about 0.27 litres).
7 Switch on the power and check gear chang-
ing movements using the test program (test
stage ”GEARENGA”).

 Scania CV AB 1995
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Opticruise

Changing the lateral stroke

cylinder
It is not necessary for the compressed air system
to be pressurized in order to remove the lateral
stroke cylinder.
1 Switch on the power. Set the driving mode
selector to neutral position.
2 Cut the power. Disconnect the hoses from
the lateral stroke cylinder.
3 Undo the fastening bolts and remove the
cylinder.
4 Lubricate the piston with brake grease, part
No. 319 308.
5 Fit the new cylinder.

05_5334
6 Fit the air hoses.
7 Switch on the power and check gear chang-
ing movements using the test program (test
stage ”GEARENGA”).

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 Gear selector housing

Gear selector housing

Dismantling
Important: Handle the selector forks with care.
Undamaged selector forks are vital for proper
operation of the gearbox.
1 Remove piston and spacer for the splitter
gear control cylinder.

2 Mark the selector forks according to posi-

tion and direction (forward/rearward).
3 Remove the ten fastening bolts, eight M10
and two M12. Remove the mounting plate
and lift out the selector forks with pivot
brackets and selector plates.

4 Remove the spring and ball. Remove the

plunger for the high/low splitter switch.
Remove the splitter selector shaft.

 Scania CV AB 1995
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Gear selector housing

5 Knock away the pivot brackets.

6 Remove the retaining rings.

7 Tap out the pivot pins and remove the selec-

tor plates.

The selector forks are changed as complete

spare parts.

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 Gear selector housing

Assembly
1 Fit the selector forks to the selector plates as
marked previously. Tap in the pins.

2 Secure with retaining rings.

3 Put the pivot bracket aside and fit the forks.

4 Fit the other pivot bracket.

 Scania CV AB 1995
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Gear selector housing

5 Fit the gearshift rod in the gear selector

housing.
Note: Turn it the right way. Fit the ball and
spring. Fit the plunger for the splitter gear
switch.

6 Lift the selector forks into position in the

gear selector housing. Bolt down the selec-
tor forks. Remember the attaching plate.

Tightening torque M 10: 47 Nm

Tightening torque M 12: 84 Nm.
Fit the piston after mounting the gear selector
housing on the gearbox.

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 Gearbox

Gearbox

Assembly

Special tools

Number Designation

87 488 Guide pins

87 596 Impact drift
87 758 Drift
88 247 Drift
98 450 Shank
99 189 Assembly sleeve
99 191 Drift

Other tools

587 585 Retaining ring pliers

Fitting the lay shaft

1 Fit the oil strainer in place with O-ring and
spacing sleeve. The spacing sleeve’s inner
chamfer should face the O-ring. Clip the oil
strainer in place.

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Gearbox

2 Fit the lay shaft front bearing outer race.

Use drift 87 758.

3 Tap in the ring until dimension A is 6 mm.

The clutch housing then presses the bearing
race into the correct position.

4 Fit the O-ring in the lay shaft’s rear bearing

seat.

5 Fit the lay shaft in its rear bearing seat. Push

the shaft forward to the front bearing seat.
Fit the bearing outer race to the rear bearing.
Centre carefully.

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 Gearbox

6 Tap the rear bearing outer race in place

using a hammer and drift.

7 Fit a 0.8 mm shim and retaining ring to the

rear bearing. Use pliers 587 585.

For measuring and adjusting axial clearance

see page 67.

 Scania CV AB 1995
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Gearbox

Fitting the reverse gear shaft

1 Mark the end of the shaft opposite the lubri-
cation hole.
2 Fit the bearings in the gearwheel and lubri-
cate with oil.

3 Fit the reverse gearwheel, long hub section

forwards, and the washers.
4 Turn the shaft so that the radial lubricating
hole faces downwards.

5 Drive in the shaft using drift 88 247.

6 Fit the shaft securing bolt using locking

compound 561 200.

Tightening torque 50 Nm.

7 Fit the overflow valve (also called dump

valve) in place with a new O-ring.
Tightening torque 45 Nm.

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 Gearbox

Fitting the mainshaft

1 Fit the strap on both sides of the second-
gear and third-gear synchromesh assembly.
Note: Make sure that the lifting strap is properly
secured.

2 Insert the rear end first. Fit the synchromesh

assembly without the latch cone and syn-
chromesh cone.
Note: Look at the marking. The chamfered spli-
nes in the driver hub should face forwards.

3 Fit the latch cone and synchromesh cone on

the front end before lowering the shaft fully.

4 Lower the shaft. Lift the end of the shaft

with the tapered end of the crowbar and
remove the strap.

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Gearbox

5 Fit the oil pipe with O-ring and spacer and

two securing bolts.
Tightening torque 26 Nm.

6 Fit the input shaft with bearing outer race.

7 Push in the outer race for the front bearing

by such an amount that dimension A is
7 mm. The clutch housing will then press
the race into its correct position.

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 Gearbox

8 Push in the outer race for the rear bearing.

9 Drive in the bearing outer race to its correct

position.

10 Fit a 0.8 mm shim.

11 Fit the retaining ring using retaining ring

pliers 587 585.
Note: Turn the retaining rings so that their open-
ings are opposite each other. The mainshaft’s
retaining ring is loaded mostly at the top and
that of the lay shaft mostly at the bottom.

 Scania CV AB 1995
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Gearbox

Fitting the clutch housing

1 Pull out the seal using impact drift 87 596.
Clean the seal surface

2 Fit a new seal. Grease the lip. Use drift

99 191 and shank 98 450. When using the
older design of drift 99 191, with only one
shoulder, the seal must not be tapped down
more that 3 mm. It is then correctly posi-
tioned when the slave cylinder is fitted. The
newer design of drift 99 191 has an extra
shoulder to correctly level the seal.

3 Fit the oil pump in place with a new gasket

on the clutch housing.

4 Bolt on the oil pump.

Tightening torque 9.5 Nm.
Note: Make sure that the pump shaft can be
rotated easily.

5 Fit assembly sleeve 99 189.

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 Gearbox

6 Apply sealing compound 584 010 to the

clutch housing.
Note: Make sure that no sealing compound gets
into the oilways.

7 Check the bearing outer races. A should not

protrude more than about 7 mm and B about
6 mm. Check that the spacers for the oil
pipe and the bottom strainer are in position.
8 Carefully centre the spacing ring between
the piston rings on the input shaft.

9 Fit two guide pins 87 488.

10 Fit the clutch housing. Make sure that the oil

pump shaft enters the square hole. Carefully
centre the piston rings. It should be possible
to press the housing down onto the gearbox
housing by hand.
11 Remove the guide pins and assembly sleeve.
12 Fit the fastening bolts. Seal with sealing
compound 584 010.

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Gearbox

13 Tighten the clutch housing retaining bolts.

Tightening torque 210 Nm.

14 Press in a new V-ring with the slave cylin-

der, greasing the lip.

15 Fit and tighten the securing bolts.

Tightening torque 22 Nm.

16 Remove the plugs from both slave cylinder

connections.
Fit the pipes and unions.

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 Gearbox

Setting bearing clearance

Special tools

Number Designation

98 075 Dial gauge

99 199 Holder

Other tools

587 250 Magnetic foot

When measuring bearing clearance, always start

with a clearance, i.e. the bearings must not be
pretensioned.
1 Fit the holder and crank 99 199 on the input
shaft.

2 Turn the gearbox in the rack so that the rear

part faces upwards.
3 Turn the input shaft 3 - 4 revolutions so that
the bearing between the mainshaft and input
shaft is correctly seated.
4 Engage a gear.
5 Rotate the shaft 5 - 6 turns so that the bear-
ings bed in.
6 Mount dial gauge 98 075 with magnetic foot
587 250 as close to the respective shaft as
possible. Apply the tip of the instrument to
the plane surface of the inner race.
7 Zero the dial gauge.

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Gearbox

8 Insert a crowbar under the lowest lay shaft

gearwheel and the mainshaft’s lowest gear-
wheel.
9 Raise the shafts using the crowbar, applying
a force of 150 - 200 N at the end of the bar.
Observe the reading on the dial at the same
time. Distinguish clearance play and spring
in the box. The end plate of the gearbox can
”give” about 0.02 mm when the shaft is
raised with the crowbar.

Note: Take care when raising the shaft with the

crowbar, as this could easily result in broken
teeth. To reduce the risk of damage, grind the
end of the crowbar as shown.

Grinding the crowbar

10 Lower the shaft and rotate the shafts again

some ten turns or so until the dial gauge
returns to 0. Repeat this measurement twice.
11 If necessary, adjust axial clearance using
shims. Available thicknessess: 0.25; 0.30;
0.40 and 0.80 mm.

Correct axial clearance:

- mainshaft: 0.12 - 0.20 mm
- lay shaft: 0.12 - 0.20 mm.
Always place a 0.8 mm shim closest to the
retaining ring.

Remove the crank 99 199.

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 Gearbox

Fitting the planetary unit

Special tools

Number Designation

87 075 Adapter
87 095 Guide pins
98 765 Splined socket
98 774 Holder
99 003 Hydraulic cylinder
99 004 Hydraulic pump
99 005-1 Dolly
99 006 Spindle
99 167 Lifting tool
99 040 Pusher adapter

Other tools

587 586 Socket

For fitting planetary gear for retarder, see book-

let entitled ”Planetary gear, Gearboxes
GR/GRH/GRS/GRSH900”.

1 Fit the spacing ring on the gearbox main-

shaft and fit the synchromesh cone on it.
2 Measure distance A and fit the requisite
number of shims.
A = 108.75 - 109.25 mm

 Scania CV AB 1995
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Gearbox

3 Fit adapter 87 075 or 99 040 on the end of

the shaft, depending on whether the oil noz-
zle is present or not.

4 Fit the sun wheel on the mainshaft’s splines.

5 Press the sun wheel on the shaft using the

hydraulic tool as shown and hydraulic pump
99 004.
Note: Mesh the synchromesh cone with the sun
wheel’s teeth during the pressing process.

! WARNING!

Danger of crushing.

 Scania CV AB 1995
70 05:03-02 en
 Gearbox

6 Fit the oil nozzle in the shaft if it is

removed. Use locking compound 561 200.
Tightening torque 84 Nm.
7 Engage two gears and high or low split. Fit
a new round nut and apply locking com-
pound to the threads.

8 Tighten by means of splined socket 98 765

for a standard planetary gear and socket
587 586 for a planetary gear with Scania
retarder and/or dual circuit control.

9 Clinch the nut.

 Scania CV AB 1995
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Gearbox

10 Fit the two guide pins 87 095.

In the case of a Scania retarder, the guide
pin that is concealed in the range gear hous-
ing must also be fitted as well as the oil tube
between the box and the retarder.
11 Fit the gasket.

12 Fit the latch cone in the correct position.

Make sure that the splines are positioned
opposite the latch balls.
Note: The distances between the splines are not
all the same.

13 Lower the planetary unit. Remove the guide

pins.

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 Gearbox

14 Fit the guide pins in place (two for a plane-

tary unit with Scania retarder and three for
others) with new O-rings.
Drive them home with a drift. Remove lift-
ing tool 99 167.
15 Fit the thirteen bolts, making sure that the
gasket is correctly positioned.
Tightening torque 50 Nm.

16 Fit new locking bolts for the guide pins. Fit

the right-hand shift cylinder in the correct
position and tighten the bolts.
Tightening torque 26 Nm.
17 Tighten the securing bolts.
Tightening torque 26 Nm.

18 Tighten the end yoke round nut.

Use splined socket 98 765.
Tightening torque 600 Nm.

 Scania CV AB 1995
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Gearbox

Tightening using measurement

First tighten the nut to 300 Nm using a
torque wrench. Use splined socket 98 765.
Mark the socket and driver as illustrated and
then tighten a further 11 mm in order to
achieve 600 Nm.

19 Clinch the nut.

 Scania CV AB 1995
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 Gearbox

Fitting the gear selector

housing and gearshift
housing

Special tools

Number Designation

99 193 Lifting tool

1 Fit the guide pins. Engage high split in the

gearbox.

2 Fit lifting tool 99 193. Fit a new gasket. Lift

the housing into place, making sure that the
forks are correctly positioned.

3 Fit the fastening bolts, leaving the marked

holes empty. Tighten the bolts.
Tightening torque 47 Nm.

 Scania CV AB 1995
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Gearbox

4 Lift the gearbox away from the stand.

5 Remove fixture 99 198 from the gearbox.

6 Fit a gasket and side cover or power take-

off. Seal the two through bolts with sealing
compound 584 010.
7 Remove lifting tool 99 193.

05_5565
8 Fit the three plungers and their springs.
Place the cover over the springs.
Tightening torque 26 Nm.

9 The splitter gear cylinder is adjusted as fol-

lows:
Fit the spacer with three new O-rings.

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 Gearbox

Push in the splitter selector shaft and spacer

as far as possible. Using a sliding caliper,
measure the distance between the top of the
splitter selector shaft and the flat surface of
the spacer.
If the shaft protrudes less than 7.0 mm, add
the necessary shims to achieve a dimension
of 7.0 mm.
Part numbers for suitable shims:
0.2 mm - part No. 1 318 958
1.0 mm - part No. 1 318 957

10 Fit the piston with a new O-ring.

Tightening torque 26 Nm.
11 Fit the air cylinder and solenoid valve for
the splitter gear.

12 Fit the gearshift housing with a new gasket.

Tightening torque 47 Nm.

13 Fit air hoses and wiring.

14 Fit a new oil filter.
In trucks with oil cooling, the spacer should
be fitted first.

 Scania CV AB 1995
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  Scania CV AB 1995
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 Wiring diagram and pneumatic circuit diagram

Wiring diagram and pneumatic circuit diagram

+L
(−H)
Split H L
13
6 Range
H L
Range

5
Range Split
12
H H
L L (NO)

11
4
3
Split
H L
+24V

−H
2 10
+L
+24V (−H)
1
9
+

(NC)
7 bar 8

7
05_5168
−NO
+24V
A Air line, pressurized / not pressurized

B Air line, pressurized

C Electric cable

1 Output shaft 8 Clutch pedal switch

2 Engine speed sensors 9 Solenoid valve (splitter interlock valve)
3 Overrevving protection 10 Splitter control cylinder with control valve
4 Joint 11 Gear selector fork
5 Range switch 12 Neutral position valve
6 Splitter control 13 Two range cylinders with one control valve
7 Air tank

 Scania CV AB 1995
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Specifications

Specifications

Exchange ratios
CL .......... 16.38 4L ............ 3.01
CH .......... 13.28 4H ........... 2.44
1L ........... 11.27 5L ............ 1.91
1H ........... 9.14 5H ........... 1.55
2L ........... 7.17 6L ............ 1.23
2H ........... 5.81 6H ........... 1.00
3L ........... 4.63 L RL ........ 14.74
3H ........... 3.75 L RH ....... 11.95

Axial clearance
Mainshaft ................................................................. 0.12 - 0.20 mm
Lay shaft ................................................................... 0.12 - 0.20 mm

Fluid volume
Gearbox + filter ........................................................ 14.9+0.5 liter
Gearbox with retarder + filter .................................. 16.5+0.5 liter
Power take-off EG600 ............................ 1.1 liter
EG610 ............................ 0.6 liter
EG620 ............................ 1.1 liter

Consumables
Sealing compound, part No. ...................................... 584 010
Locking compound part No. ..................................... 561 200

 Scania CV AB 1995
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 Specifications

Tightening torques

Gearbox
Round nut on mainshaft ............................................ 400 Nm
+ locking
compound
Lock bolt for reverse gear shaft ................................ 50 Nm
+ locking
compound
Overflow valve .......................................................... 45 Nm
Oil pipe ...................................................................... 26 Nm
Oil nozzle in shaft ..................................................... 80 Nm
Bolts for oil pump ..................................................... 9.5 Nm
Securing bolts for clutch housing ............................. 210 Nm
Securing bolts for support sleeve .............................. 26 Nm
Round nut, end yoke ................................................. 600 Nm
Drain and level plugs ................................................ 100 Nm

Gear selector housing

Cover over springs .................................................... 25 Nm
Bolt for split piston ................................................... 26 Nm
Bolts for split cylinder .............................................. 26 Nm
Securing bolts for cover M 10 ............. 47 Nm
M 12 ............. 84 Nm

Gearshift housing
Selector arm (2 pcs) .................................................. 92 Nm
Securing bolts for coulisse ........................................ 25 Nm
+ locking
compound
Sleeve for lateral stroke spring .................................. 47 Nm
Switch ....................................................................... 25 Nm
Securing bolts against gear selector housing ............ 47 Nm

 Scania CV AB 1995
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Specifications

Fitting parts

These items ought to be in stock at the workshop for reconditioning GRS900 gearboxes.
2
1 3 7

5
6

05_5647
1 Retaining rings for input shaft bearing 4 Shims for mainshaft
Part No. Thickness Part No. Thickness
1 113 900 2.20 mm 378 637 0.25 mm
1 113 901 2.25 mm 378 638 0.30 mm
1 113 902 2.30 mm 378 639 0.40 mm
1 113 903 2.35 mm 5 Shims for high-range cone
1 113 904 2.40 mm Part No. Thickness
1 113 905 2.45 mm
1 113 913 0.25 mm
1 113 906 2.50 mm
1 11 914 1.00 mm
1 324 647 2.55 mm
1 324 648 2.60 mm 6 Shims for lay shaft
1 324 649 2.65 mm Part No. Thickness
2 Shims for splitter gearwheel 1 104 034 0.25 mm
1 104 035 0.30 mm
Part No. Thickness
1 104 036 0.40 mm
1 104 069 0.30 mm
1 104 070 0.40 mm 7 Shims for splitter control
1 104 071 0.50 mm Part No. Thickness
3 Spacing rings for splitter gearwheel 1 318 958 0.2 mm
1 318 957 1.0 mm
Part No. Thickness
1 302 731 9.50 mm
1 302 732 9.52 mm
1 302 733 9.54 mm
1 302 734 9.56 mm
1 302 735 9.58 mm

 Scania CV AB 1995
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 Special tools

Special tools

Number Designation Tool board

79 046 Drift G1
87 000 Drift AM2
87 075 Adapter G3
87 089 Drift AM2, D3
87 095 Guide pins D4, G2

87 237 Support drift G2

87 362 Drift D3
87 446 Drift AD2
87 474 Drift D1
87 488 Guide pins R2

87 550 Drift AD2

87 596 Impact drift D2
87 758 Drift G1
87 932 Drift D3, G1
88 247 Drift G1

88 292 Shank G2
98 075 Dial gauge D2
98 224 Press plate G1
98 322 Lifting tool G2
98 334 Drift G3

98 450 Shank R2, AD2, AM1

98 522 Drift D1
98 575 Drift G2
98 636 Drift G1
98 638 Drift G3

98 647 Support drift G2

98 765 Splined socket G2
98 774 Holder AD3
99 003 Hydraulic cylinder H1
99 004 Hydraulic pump H1

99 005-1 Dolly H1
99 006 Spindle H1

 Scania CV AB 1995
05:03-02 en 83
Special tools

Number Designation Tool board

99 040 Pusher adapter H1

99 074 Impact drift D1
99 127 Drift AM1
99 136 Hollow drift P1
99 140 Support ring P1

99 141 Support ring P1

99 142 Support ring P1
99 143 Split support ring P1
99 154 Support drift G2
99 167 Lifting tool G1

99 189 Assembly sleeve G4

99 190 Drift G4
99 191 Drift G4
99 193 Lifting tool G4
99 198 Fixture

99 199 Holder G4
99 201 Support ring P1

Other tools

587 250 Magnetic foot

587 312 Retaining ring pliers
587 316 Holder
587 318 Extractor plate
587 319 Puller

587 511 Puller

587 530 Puller
587 585 Retaining ring pliers
587 586 Socket
587 600 Socket

 Scania CV AB 1995
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