Hydraulic Actuated Clutch - Heavy Haulers RV Resource Guide
Contents
1. Service Procedures W4000782 Disconnect the rear slip yoke by dis 1 2 socket connecting the U joints four bolts located behind the center bearing sup port 3 Disconnect the U joint at the transmis 1 2 socket sion yoke 4 Remove center bearing support two 11 16 socket bolts 5 8 wrench ratchet 5 W4000806 Remove fuel tank brace 18 mm socket 15 mm wrench ratchet Group 41 Hydraulically Actuated Clutch Service Procedures W4000807 W4000860 Remove the engine cross member 18 mm socket Disconnect the wire harness from the side cutters from the top cover of the engine nodal wrench 15 following sensors and cut the wire ties mounts mm socket wrench 1 Transmission temperature sensor 2 VSS vehicle speed sensor 3 Reverse lamps sensor 7 4 Range solenoid W4000783 Remove the transmission oil filter 14 mm socket cover to access the coolant hoses Cut side cutters the hose clamp to remove the hoses W4000861 Remove air lines 1 through 4 and L 3 8 open end brackets wrench 5 8 8 open end Remove the coolant hose support 13 mm socket wrench 18 brackets 10 mm socket mm open end ratchet wrench 39 Group 41 Hydraulically Actuated Clutch 11 W4000846 Remove the two springs on the shifter pry bar High spring tension Risk of flying debris Always use proper eye and hand protection W4000847 side cutters 19 mm wrench Remove the cotter key at2. T2006733 Remove the flywheel pilot bearing with tool 8121 puller 1821 2 Clean the flywheel and check for dam age T2006734 Set up a dial indicator probe on the fly wheel so that the probe is against the flywheel at a radius of 150 mm 5 9 in from the center Set the dial indicator to zero 0 Rotate the flywheel with tool 6956 Note the reading on the dial indicator during flywheel rotation Group 41 Hydraulically Actuated Clutch 4 If the dial indicator reading exceeded 0 20 mm 0 0079 in remove the fly wheel and inspect and clean the surface between the flywheel and the crankshaft Note If the flywheel is out of specifi cation after cleaning the crankshaft flange the flywheel should be re placed Refer to TSI Service Manual 210 600 Basic Engine VE D12 ee ap T AIAN Us SS T2006732 Install the new flywheel pilot bearing 2564 using drift 2564 Service Procedures Volvo clutch servo removal 1 A ME wg us Hm S W4000867 Remove the air line to the servo cylin pliers der Remove the cotter pins from the front and rear clevis pins and remove both clevis pins Lower the servo to the floor W4000867 Disconnect the vent line and the hy 19 mm open draulic line from the servo cylinder end wrench 17 mm open Note A suitable drain pan will be end wrench needed to catch leakage from the hy draulic line 23 Group 41 Hydraulically Actuated Cl
3. NC USA Order number PV776 TSP24581 1 1996 Volvo GM Heavy Truck Greensboro NC USA All rights reserved No part of this publication may be reproduced stored in retrieval system or transmitted in any forms by any means electronic me chanical photocopying recording or otherwise without the prior written permission of Volvo GM Heavy Truck Contents gr MATTHEUM 3 About this Service Information aususesnsesinutid Me GERI LSU NSREKRTE MEM NPI E pED MAE 3 NN MTM Hor Um 5 sfr ger ETUR NOTUM 5 He ET ER EEE PER 5 Transmission Slave CYIMOSI RE EEE 6 a E ERE M E 7 Biden siup 7 pis eee rom 9 BUS INE NG 9 Augu n MERERI 10 Design and Function rrnnnnnnnnnnennnnnnnrnnnnnnnvnnnnnnennnnnnrrnnnnnnennnnsenennnnnne 11 Clutch and HE Cluteh System uucisssepsieieeni etui ieu re PELEAS rea er RE iE 11 BE EEE NR HURRS 11 FN asesnbse eM EU MICI MIIIENISDIB MEN MM ado IMPIIS SIDE 14 lpdie Modicie o i E 19 MN NN 19 Clutch plate changing and installation sseesessssssse 20 Flywheel pilot bearing replacing sseeeeeereeeeeene 22 MOO CIC Servo removal re 23 Volvo bee EE 24 Volvo clutch servo adjustment iesssssdodectekb qum IUUD Dead Rb VAM UU RI 24 Master cylinder removal auseseesebkrlktedukbebtdtdadqid Un dd FREE SERI M AFIN REA Gee RRIA 25 Master cylinder installation seas DUE OHIO MM Maud 27 Clutch slave cylinder removal RE 31 Clutch
4. 06 1 14 Lever length L mm in mmerrrnnnnnnnenrrnnnnnnnvnnrnnnnnsvnnnnnnn 150 5 9 130 5 12 Fuller or Rockwell Transmissions Hydraulic Clutch Slave P N 8075008 6 Group 41 Hydraulically Actuated Clutch Specifications Hydraulic System TG IWAN MR RETE RU LT Tm DOT 4 SAE J1703 PFU Reservo GAP CE 0 15 liter 0 16 qts Total Hydraulic System Capacity mene erdaeer em dee hee 0 3 liter 0 3 ats Tightening Torques Component Nm ft Ibs Clutch Housing to Flywheel CIE Io EEE ER 37 4 27 3 CEDE Rene ae D te cU ren CM MU EE E EE E AE 65 6 48 4 Spicer ES Ped 15 SE 60 7 45 5 Intermediate Ring Volvo clutches c STI DE ONERE TR 26 2 19 x 1 Clutch Servo Volvo koc Hb PRS 60 10 45 7 AIC MEAN vr 24 2 18 1 Fod PET NPE var 10 2 7 1 Hydraulic COANECNON iei iu aeo ob b I Qiu b sen chan leet 45 5 33 4 Clutch Slave Cylinder non Volvo MOUNTING DONS sesira enna a A E EO AR 35 26 Hydraulic connection line to fitting rrrrrrrrrrnrrnnnnrvvrrrnnnnnrrvrrrnnnerrrnrnnnsnnsennnnnnsnsseen 40 5 30 4 Hydraulic connection fitting to cylinder sees 20 15 Clutch Master Cylinder Memo NNN 24 4 18 3 Hydraul ej 1 as EE NINE 40 5 30 4 Group 41 Hydraulically Actuated Clutch Tools Tools Special tools The following special tools are required for work on the Volvo VN Series Hydraulic Clutch oystem The tools can be ordered from the Volv
5. 36 W4000800 Note This procedure requires two technicians Fully depress the clutch pedal until it contacts the stop 3 and hold it there 3 Insert a ruler into the inhibitor valve metric ruler hole until it is against the clutch pedal 40 torx bit lever Adjust the flat head adjusting ratchet screw 1 to a distance of 53 5 mm 2 10 in from the flat of the screw head to the depressed clutch pedal lever Group 41 Hydraulically Actuated Clutch Service Procedures W4000818 Remove the ruler and slide the in 13 mm socket hibitor valve into its bore Slide the 13 mm valve in until it bottoms against the flat wrench head adjusting screw Tighten pinch torque bolt and nut to a torque of 24 Nm wrench 3 ex 18 ft lb tension Note Apply grease around the out side diameter of the valve before installation 37 Group 41 Hydraulically Actuated Clutch Transmission removal Volvo transmission Other special equipment Transmission jack 1 W2002059 A N DANGER Risk of poisoning Coolant is toxic Do not drink coolant Use proper eye and hand protection when handling Keep coolant out of reach from children and animals Risk of burns Engine and fluids may be hot Never remove the coolant drain plug or the expansion tank cap when the engine is hot Allow the engine to cool before ser vicing Drain the coolant from the radiator The drain is located on the bottom of the radiator 38
6. inter mediate pressure plate straps two clutch discs and four centering lugs 11 Group 41 Hydraulically Actuated Clutch Volvo Clutch Plate s The Volvo clutch plates are dry with linings on both sides Each clutch plate consists of a disc damper springs hub and linings The disc is connected to the hub by friction elements and damper springs to provide a smooth engagement and eliminate engine pulses W4000794 Flywheel plate Volvo Pressure Plate The pressure plate is a powerful diaphragm spring It is mounted to the flywheel with six mounting bolts When the clutch pedal is depressed the spring force is removed from the clutch plates and absorbed by the release bearing The clutch plates are then disengaged and stop transmitting torque to the transmission 12 Clutch and Hydraulic Clutch System The front plate hub is splined onto the transmission s input shaft The rear plate is splined onto the outer diameter of the front plate hub The linings are organic non asbestos material and are riveted to the disc W4000795 Gearbox plate W4000789 Group 41 Hydraulically Actuated Clutch Clutch and Hydraulic Clutch System Spicer Clutch The Spicer Easy Pedal Plus 1552 double plate clutch is a spring type clutch that is controlled by a hydraulic slave cylinder The clutch engagement disengagement is a result of the slave cylinder rotating the cross shaft and fork assembly The Spicer double plate clut
7. pedal effort may make the vehicle hard to control Repair a damaged servo before driving vehicle Driving a vehicle without servo air pressure could result in damage to the vehicle or personal injury 16 Group 41 Hydraulically Actuated Clutch Clutch and Hydraulic Clutch System Master Cylinder with Slave Cylinder Fuller or Rockwell Transmissions W4000781 Master Cylinder The clutch pedal activates the master cylinder When the clutch pedal is depressed the clutch rod moves downward pushing the plunger into the cylinder Plunger movement into the cylinder forces the fluid through the hydraulic lines and into the clutch slave cylinder As the plunger is forced into the cylinder the fluid supply duct from the reservoir is closed When the clutch pedal is released the clutch rod and plunger returns to the rest position and the fluid supply duct opens W4000840 Slave Cylinder The slave cylinder is connected to the master cylinder through a steel braided hydraulic hose The slave cylinder operates on the hydraulic pressure from the master cylinder The adjustment indicator shows whether the clutch is properly adjusted W4000816 17 18 Group 41 Hydraulically Actuated Clutch Service Procedures Service Procedures Clutch removal Volvo clutch Transmission removed from vehicle Other special equipment 1821 Puller 6857 Lifting tool 6902 Centering drift T4006506 Install the centering drift 690
8. the rod end nut of the shift linkage Remove the rod end nut Remove the rod end from the side control lever 40 Service Procedures W4000848 Remove the shifter support assembly Move the shifter linkage to the side out of the way 14 mm socket 14 W4000862 5 8 open end wrench side cutters Remove the servo air supply line W4000863 Remove the two clevis pins securing side cutters the servo Move the servo to the side out of the way Group 41 Hydraulically Actuated Clutch Service Procedures 16 18 Remove the transmission from under the truck Note In some applications it may be necessary to raise the vehicle with a floor jack and jack stands This is for the transmission and transmission jack to be able to clear the vehicle frame W4000788 Place a transmission jack under the transmission transmission Secure the transmission jack 18 mm to the jack Socket 17 Na e i XK GANN ws ON 1 SG QU N ISSN VE ON Eu LTD AT BEE TG V ZA C3 p 2 67 EX W4000828 1 Nut 2 Stud Remove the transmission mounting 18 mm socket bolts and remove the transmission extension from the engine Transmission is top heavy and may be unstable Failure to remove the transmission carefully could result in damage to the transmission and personal injury 41 Group 41 Hydraulically Actuated Clutch Non Volvo transmission This procedure is meant to be a guide for removing no
9. to position the cover over the studs Note Be careful not to damage the cover when installing 13 Install three torx screws and the plas 10 mm socket tic nut on the center of the lower dash 6 extension COVer 25 torx driver Stop bleeding when the fluid is at the 10 mm wrench minimum level indicated on the side of the reservoir Close the bleeder screw Torque bleed screw to 10 Nm 7 ft lb Note Use clean DOT 4 fluid only 9 Disconnect the bleeder tool and re move 29 Group 41 Hydraulically Actuated Clutch 14 W4000855 Install the left panel Install the diag 20 torx driver nostic connector Install the heater 10 mm socket hose three torx screws and the plastic 6 extension nut ratchet 15 W3000648 Install the upper cover on the steering 20 torx driver column with three torx screws 30 Service Procedures W3000655 Install the two clips at the bottom of the steering column cover W3000654 Put the dust covers in place on the turn signal and windshield wiper switches Group 41 Hydraulically Actuated Clutch Clutch slave cylinder removal 1 W4000851 Remove the fluid hose from the slave 19 mm open cylinder end wrench Note Use a catch pan to drain the fluid 2 W4000870 Remove the slave cylinder mounting bolts with the operating range indica tor Remove the clevis pin 12 mm socket ratchet 3 Remove the fluid hose fitting 19 mm wrench Se
10. 2 into the clutch W4000789 Loosen the pressure plate mounting 17 mm socket bolts ratchet W4000790 Using a floor jack with tool 6857 place the lifting hook of tool 6857 between the pressure plate spring and housing Remove the clutch mounting bolts and remove the clutch from the flywheel 4 Remove clutch from under the vehicle 6857 Group 41 Hydraulically Actuated Clutch Clutch plate changing and in stallation Volvo clutch Clutch removed from vehicle double plate type clutch Part no 1161138 Heat resistant grease Special tools 6902 centering drift W4000791 Punch mark the pressure plate hous ing and the intermediate plate for proper alignment W4000792 6mm hex socket ratchet Remove the four hex head socket screws that hold together the pressure plate housing and intermediate plate Remove the pressure plate housing and the gearbox side clutch plate 20 Service Procedures 3 Inspect the clutch parts e Pressure plate housing e Intermediate plate e Clutch plates engine side and gearbox side e Release bearing Note Refer to TSI Service Manual 411 600 Clutch Pull type Volvo for additional clutch overhaul informa tion 4 Grease input shaft spline with heat 6mm hex resistant grease p n 1161138 Install socket the new engine side clutch plate on ratchet torque the input shaft The side marked wrench Flywheel side non asbestos should be toward the flyw
11. 4 W4000870 Install clutch slave cylinder Torque 12 mm socket the mounting bolts to 35 6 Nm 26 6 ft lb Use a new cotter pin to secure the clevis pin W4000802 Install the transmission oil cooler and 9 16 socket hoses Torque the 3 8 bolt to wrench 5 8 48 Nm 85 ft lb and the 7 16 bolt to wrench 7 8 0 85 Nm 50 65 ft lb Use pipe wrench sealer on oil cooler hoses 49 Group 41 Hydraulically Actuated Clutch 15 W4000782 Install the drive shaft and center bear ing Center bearing to bracket torque to 105 Nm 78 ft Ib 1 2 12 pt socket 15 mm socket 18 mm wrench Note Refer to the driveline manufac turer for the proper torque values n Install the fuel tank brace W4000806 15 mm socket 18 mm wrench 17 Fill the transmission with the manufac turers recommended oil Torque drain plug to 82 100 Nm 60 75 ft lb 9 16 wrench 18 Install the battery cable 19 Road test the vehicle to check for oil leaks and air leaks 50 Service Procedures Shift linkage removal 1 Remove the upper shift lever boot mounting bolts Pull the upper and lower shift lever boots up on the shift lever so work be carried out through the cab floor 12 mm socket 6 extension W4000849 Disconnect the air lines from the gear 10 mm open lever knob and cut the plastic ties end wrench 18 mm open end wrench side cutters W4000847 Remove
12. 4000828 1 mounting nut 2 stud Install transmission mounting nuts 18 mm socket hand tight Remove the transmission extension jack Torque transmission mounting torque wrench nuts to 92 Nm 68 ft Ib W4000864 Make sure the clutch fork is in the 4 proper position for installing the trans mission The fork and spring should be behind the ears of the release bear ing when the transmission is installed W4000863 Install the clutch servo clevis pins with side cutters new cotter pins 45 Group 41 Hydraulically Actuated Clutch KR W4000862 Connect the servo air supply line 5 8 open Torque to 24 Nm 18 ft lb wrench W4000861 Install the air lines to the transmission 3 8 open end wrench 5 8 open end wrench 18 mm open end wrench 7 Install the shift and support assembly using the shift linkage installation pro cedure 46 Service Procedures W4000860 Install the wire harness and connect it to the following sensors KON 9 Tie wrap the wires and air lines mak ing sure they are properly routed Install the transmission cooler hoses with new hose clamps Install the oil filter cover three bolts 11 Connect all L brackets for the cooler houses Transmission temperature sensor VSS vehicle speed sensor Reverse lamps sensor Range solenoid side cutters tie wraps W4000783 14 mm socket extension ratchet 14 mm socket 10 mm so
13. Service Manual Trucks Group 41 Hydraulically Actuated Clutch Including transmission removal VNL VNM PV776 TSP24581 1 VOLVO Foreword The descriptions and service procedures contained in this manual are based on design and method studies up to October 1996 The products are under continuous development Vehicles and components produced after the above date may therefore have different specifications and repair methods When this is believed to have a significant bearing on this manual supplementary service bulletins will be issued to cover the changes The new edition of this manual will update the changes In service procedures where the title incorporates an operation number this is a reference to an S R T Standard Repair Time Service procedures which do not include an operation number in the title are for general information and no reference is made to an S R T The following levels of observations cautions and warnings are used in this Service Documentation Note Indicates a procedure practice or condition that must be followed in order to have the vehicle or component function in the manner intended Caution Indicates an unsafe practice where damage to the product could occur Warning Indicates an unsafe practice where personal injury or severe damage to the product could occur Danger Indicates an unsafe practice where serious personal injury or death could occur Volvo GM Heavy Truck Greensboro
14. and measure from the upper edge of the clutch pedal to the floor E Press the clutch pedal until it strikes the lower stop screw and re measure from the upper edge of the clutch pedal to the floor The pedal movement from splitter to lower stop screw should be 40 5 mm 1 5 13 64 in W4000873 Measure the clutch servo stroke D ruler Stroke should be 27 29 mm 1 9 16 1 9 64 in Service Procedures Master cylinder removal 1 W4000855 Pull the floor mat back and remove 10 mm socket the plastic nuts fastening the left 6 extension panel Remove the three torx screws 20 torx bit and the diagnostic connector Pull the heater hose out of cover and remove the cover W3000648 Remove the cover on the steering 20 torx bit 3 wheel column by removing the ignition extension key and the three torx screws 25 Group 41 Hydraulically Actuated Clutch Service Procedures W3000654 Pull the dust covers back on the turn signal and windshield wiper stalks 4 W4000851 Remove four torx screws from the 10 mm socket Loosen and remove the fluid line from 19 mm open center dash cover Pull the floor mat 6 extension the slave cylinder Drain the brake end wrench back and remove the plastic nut 20 torx bit fluid into a drain pan or suitable con 17 mm open tainer Install the fluid line back onto end wrench the slave cylinder to keep contami 5 nants out of the system W3000655 Remove the two clips at
15. ch consist of a pressure plate release bearing intermediate plate Positive Separator Pin two clutch plates and a Kwik adjust W4000831 Spicer Clutch Plates The Spicer clutch uses ceramic linings on both clutch plates The plates are dampened with springs to reduce torsional vibrations W4000832 Spicer Pressure Plate The Spicer pressure plate is a spring type with 9 coil springs W4000831 13 Group 41 Hydraulically Actuated Clutch Function Clutch and Hydraulic Clutch System Master Cylinder with Pneumatic Servo Volvo Transmissions The Volvo pneumatic servo operates on hydraulic pres sure from the clutch master cylinder and is assisted with Master Cylinder W4000840 14 W4000835 air pressure The servo consists of an air cylinder reac tion plunger and control valve The clutch pedal activates the master cylinder When the clutch pedal is depressed the clutch rod moves downward pushing the plunger into the cylinder Plunger movement into the cylinder forces the fluid through the hydraulic lines and into the clutch servo As the plunger is forced into the cylinder the fluid supply duct from the reservoir is closed When the clutch pedal is released the clutch rod and plunger return to the rest position and the fluid supply duct opens Group 41 Hydraulically Actuated Clutch Clutch and Hydraulic Clutch System Pneumatic Servo Clutch engagement W4000857 When the clutch
16. cket ratchet Group 41 Hydraulically Actuated Clutch W4000807 15 mm socket Install the engine cross member Torque mount bolts to 105 20 Nm wrench 18 78 15 ft lb mm socket wrench ex tension 13 Connect the front section of the drive 1 2 12 point shaft to the transmission yoke and in socket 11 16 stall the center bearing Torque center socket 5 8 bearing mount bolts to 105 Nm wrench 78 ft lb Note Refer to the driveline manufac ture for the proper torque of the U joint yoke 14 W4000782 Connect the slip yoke of the rear sec 1 2 12 point tion to the front drive shaft socket torque wrench Note Refer to the driveline manufac turer for the proper torque of the U joint yoke Service Procedures W4000806 15 mm socket 18 mm socket ratchet torque wrench Install fuel tank brace 16 W2002058 Fill cooling system with the proper coolant mixture Note Refer to TSI bulletin 260 600 01 Coolant Requirements Volvo VE D12 for proper coolant concentra tion Note Maximum fill rate of 2 5 gallons per minute 47 Group 41 Hydraulically Actuated Clutch Non Volvo transmission This procedure is meant to be a guide for installing non Volvo transmissions Refer to the transmission manufacturer s literature for more information Other special equipment Transmission jack W4000808 Set transmission on a transmission jack Secure the transmi
17. e Volvo Transmissions Volvo air assisted hydraulic servo e Other Transmissions hydraulic slave cylinder Note For more clutch overhaul instructions please refer to the Volvo Service Manual 411 600 Clutch Pull Type Volvo Group 41 Hydraulically Actuated Clutch Specifications Clutch Volvo Model Size Max Torque mm in Nm Ibeft CL43S 0 single plate 430 17 1850 1365 CL38D O double plate 380 15 1980 1460 Spicer Model Size Max Torque mm in Nm Ib ft Easy Pedal Plus 1552 394 15 5 1730 1275 double plate Clutch Master Cylinder O P N 1628218 Volvo or 8076243 NON foo rore A E N 1970 1450 2240 1650 Spline Size 10 SAE 10 SAE Spline Size 10 SAE Specifications Facing Material organic organic Facing Material ceramic Non serviceable Group 41 Hydraulically Actuated Clutch Specifications Transmission Slave Cylinder Note Vehicles equipped with a Volvo transmission use a equipped with a non Volvo transmission use a hydraulic pneumatic hydraulic servo for clutch operation Vehicles slave cylinder Volvo Transmissions Volvo Clutch Servo Air assisted hydraulie evliridel 42 P N 1521371 Measurement CL43S O clutch CL38D O clutch mmi in mm in Basic Setting AF ve 55 1 5 2 16 0 06 55 1 5 2 16 0 06 Measurement B mm in seseeeeeseeeeeeeene Max 115 4 53 Max 115 4 53 SKE NNM 4 27 29 1 06 1 14 27 29 1
18. heel Pull the clutch plate backwards and for wards on the shaft to properly spread the grease 5 Remove the new engine side clutch plate from the input shaft Remove any excess grease so it will not contami nate the clutch plates during operation Group 41 Hydraulically Actuated Clutch W4000795 Place the gear box side clutch plate on intermediate plate Note The side marked pressure plate side should be toward the pressure plate housing facing the gearbox Service Procedures W4000792 Install the four hex head socket screws and tighten them evenly W4000796 Torque the hex screws to 26 2 Nm 19 1 ft lb W4000791 Place the pressure plate on the inter 6mm hex mediate plate and align the punch socket marks T4006506 Using a floor jack with tool 6857 place the lifting hook of tool 6857 between the pressure plate spring and housing Install the centering drift 6902 through the clutch and flywheel side clutch disc Note Flywheel side must be fac ing the flywheel 21 Group 41 Hydraulically Actuated Clutch 11 W4000790 Install the clutch to the flywheel using 18 mm socket centering drift 6902 Hand tighten bolts torque evenly to compress pressure plate wrench 6857 Torque the nuts to 85 Nm 63 ft lb 6902 22 Service Procedures Flywheel pilot bearing replac ing VE D12 engine Clutch removed Special tools 1821 puller 2564 drift 6956 cranking tool
19. ket exten sion 1 2 drive ratchet drain pan 11 W4000869 1 temperature sender Remove the temperature sender 1 5 16 wrench from the lower left side of the trans mission 12 Support the engine with a suitable tool 13 W4000808 Support the transmission with the transmission jack and secure the transmission to the jack 43 Group 41 Hydraulically Actuated Clutch W4000854 Remove the transmission mounting bolts and remove the transmission from the engine Transmission is top heavy and may be unstable Failure to remove the transmission carefully could result in damage to the transmission and personal injury 15 Remove the transmission from under the truck Note In some applications it may be necessary to raise the vehicle with a floor jack and jack stands This is for the transmission and transmission jack to be able to clear the vehicle frame 44 Service Procedures Transmission installation Volvo transmission Other special equipment Transmission jack 1 Move the transmission under the truck Jack the transmission into posi tion to align the input shaft Grease input shaft spline with high heat resistant grease p n 1161138 Note Remove any excess grease to avoid contaminating the clutch plates W4000788 transmission jack 18 mm wrench 18 mm socket extension Group 41 Hydraulically Actuated Clutch Service Procedures W
20. ly Actuated Clutch Service Procedures W4000819 Install master cylinder Make sure the 13 mm deep O ring is fitted around the neck of the swivel 6 ex master cylinder before the cylinder is tension inserted into the pedal plate assembly torque wrench Press the clutch pedal down to access the two mounting bolts Torque mount W4000850 Tighten 45 degree fitting to proper an 12 mm open gle and install the fluid line with a new end wrench O ring Torque fluid line to 40x 5 Nm 17 mm open ing bolts to 24 4 Nm 18 3 ft lb 30 4 ft lb end wrench 17 mm crow 4 foot Install the clutch pedal return spring Note Lubricate the spring end with 6 grease p n 8708166 W4000870 Remove the two slave cylinder mount 12 mm socket ing bolts and the clevis pin ratchet pliers 28 Group 41 Hydraulically Actuated Clutch Service Procedures BSS W4000810 W4000870 Open the bleed screw and connect the 10mm Install the clevis pin and the slave 12 mm socket bleed tool Clean the reservoir filler wrench bleed cylinder mounting bolts with the oper pliers cap area and remove the cap Hold tool 6928 ating range tag Torque the mounting the slave cylinder with the bleeder bolts to 35 Nm 26 ft Ib screw at the lowest point and turn the bleed pump on 11 Check for the correct operation of the 8 clutch Re check fluid level 12 Install the lower steering column cover with plastic rivets pull floor mat back
21. n Volvo transmissions Refer to the transmission manufacturer s literature for more information Other special equipment Transmission jack 1 Remove the battery cable 9 16 open end wrench 2 Remove the drive shaft center bear 1 2 12 point ing and U joint at the rear of the transmission socket 15 mm socket 18 mm wrench W4000806 Remove the fuel tank brace 15 mm socket 18 mm wrench W4000802 9 16 socket 9 16 wrench 5 8 wrench 7 8 open end wrench Remove the oil cooler and the oil cooler hoses at the transmission 42 Service Procedures 5 Remove the necessary air lines and 6 mm hex tie down clamps socket 12 mm socket side cutters W4000812 1 temperature sender 2 reverse light sender 3 vehicle speed sensor ECU 4 vehicle speed sender speedometer Remove the wires at the sensor con side nectors and tie down clamps cutters 9 16 socket W4000868 Remove the gear shifter lever by loos ening the clamp bolt on the shift tower 11 16 socket 5 8 wrench Service Procedures Group 41 Hydraulically Actuated Clutch W4000870 Remove the slave cylinder by remov ing the clevis pin and the two mounting bolts W4000807 Remove the cross member and the top half of the engine transmission nodal mounts 10 Drain gear oil into a suitable container 12 mm socket pliers 15 mm wrench socket 18 mm wrench soc
22. o GM Heavy Truck Corporation W4000833 999 6851 Adjustment gauge 999 6857 Lifting tool 999 1821 Slide puller 999 6896 Adapting fixture 999 6928 Bleeder used with 6857 999 6902 Centering drift Group 41 Hydraulically Actuated Clutch Tools Other equipment The following items are considered common shop equipment and are necessary for the repair procedures in this manual W4000817 Pinch pliers Pocket ruler Transmission jack Feeler gauges 10 Group 41 Hydraulically Actuated Clutch Clutch and Hydraulic Clutch System Design and Function Clutch and Hydraulic Clutch System Design Volvo Clutches The Volvo dry plate clutches are specifically matched to engine and transmission combinations Volvo uses two types of dry plate clutches single plate and double plate The double plate is mainly used for heavy duty transport purposes All of the clutches are of the diaphragm spring type and are controlled by an air assisted hydraulic servo 2 as C Ex Q W4000821 The single plate clutch consists of a pressure plate release bearing and one clutch disc W4000835 The clutch movement engagement disengagement is a result of the servo rotating the cross shaft fork assembly These clutches are called pull type because the fork assembly pulls the release bearing rearward to disengage the clutch W4000822 The double plate clutch consists of a pressure plate release bearing
23. o install op erating range indicator Torque bolts to 35 Nm 26 ft lb 10 Check for proper clutch operation Re check fluid level Group 41 Hydraulically Actuated Clutch Clutch bleeding procedure 1 Place the pick up tube in a 4 liter one gallon can of DOT 4 brake fluid 2 Plug the fluid pump wire into the dash cigarette lighter receptacle 3 Connect the bleed hose to the slave cylinder bleed nipple 4 Loosen the bleed nipple about one turn and use the metal C clamp to lock the bleeder hose onto the nipple 5 Remove the reservoir cap 6928 11 mm wrench Service Procedures W4000836 6 Using the ON OFF switch on the wire turn ON the switch to start the pump When the fluid has reached the level of the reservoir FULL mark turn OFF the pump Note Watch the fluid level in the reservoir to avoid it overspilling onto the paint 7 Close the bleeder nipple Remove the clamp and hose Torque the nipple to 10 2 5 Nm 7 1 8 ft lb 11 mm wrench 8 Check the clutch operation 9 Check the fluid level and top off as necessary Replace the cap 33 Group 41 Hydraulically Actuated Clutch Service Procedures Upper clutch pedal adjustment Lower clutch pedal adjustment 1 1 W4000798 utens Insert the measuring instrument 13 mm Measure the play 3 in the clutch 13 mm through the opening in the panel for wrench 4 mm pedal at the free position Adjust the wrench 4 mm the clutch
24. pedal Measure the amount Allen wrench upper screw 2 until 4 8 mm Allen wrench the adjusting screw extends from the 5 32 5 16 in play is obtained inside of the casting Adjust the lower screw 2 until it extends 19 mm Note Clutch pedal play is the clear 3 4 in from the inside of the casting ance between the clutch rod and the piston in the master cylinder Clutch adjustment does not affect pedal play 2 Torque jam nut 1 to 24 Nm 13 mm deep socket 10 2 extension Torque jam nut 1 to 24 Nm 18 ft lb 13mm deep torque wrench Socket 10 extension torque wrench 34 Group 41 Hydraulically Actuated Clutch Service Procedures Micro switch adjustment W4000855 Install the left side clutch pedal panel W4000855 Remove the left side clutch pedal 10 mm panel wrench torx bit 25 2 W4000801 With the clutch pedal in the free posi 10 mm wrench tion place a 3 mm thick feeler gauge on top of the L bracket Rotate the mi cro switch assembly down until the switch bottoms out then tighten the mounting screw Torque to 10 Nm 7 5 ft lb 25 torx bit 35 Group 41 Hydraulically Actuated Clutch Inhibitor valve splitter adjust Service Procedures W4000818 Note The lower clutch pedal adjust 13 mm socket ment must be performed before the 13 mm inhibitor valve adjustment can be wrench made ratchet 3 ex tension Loosen the pinch bolt and nut Re move the inhibitor valve
25. pedal is pressed hydraulic pressure 10 As the reaction piston moves further the rubber peg 4 increases and the reaction piston 3 is pressed in the is pushed off its seat 4b allowing pressurized air into the direction of the arrow This movement first shuts the air chamber 5 As a result of the increased air pressure control valves upper seat 4b and then the air outlet duct the piston 7 moves in the direction of the arrow 6 Fully depressed W4000858 The reduction in hydraulic pressure allows the air pressure rubber peg 4 are held in their positions until the position to push back the control valve 4b stopping the air supply of the clutch pedal is changed Pressure is now stabilized the reaction piston 3 and 15 Group 41 Hydraulically Actuated Clutch Clutch and Hydraulic Clutch System Released W4000859 When the clutch pedal is released hydraulic pressure is and opens the air outlet duct 6 Airis now released from lowered and the pressure spring 11 presses back the the air chamber 5 and the piston 7 is returned to its rest reaction piston The rubber peg 4 closes the air supply position by the force of the pressure plate spring Servo Failure If air pressure drops or the air system does not supply air pressure the servo will continue to function on hydraulic pressure however this will require greater pedal effort Increased pedal effort is required if servo air pressure is lost Increased
26. rvice Procedures Clutch slave cylinder installa tion 1 Install a new sealing washer on the 19 mm open fluid hose fitting and install the fitting end wrench Torque the fitting to 20 Nm 15 ft lb 19 mm crow foot 2 Mount the slave cylinder to the trans mission temporarily with the two mounting bolts 3 W4000851 Install the fluid hose with a new 19 mm open O ring Torque the hose to 40 5 Nm end wrench 30 4 ft lb 17 mm open end wrench 17 mm crow foot 4 Remove the slave cylinder for bleed ing 31 Group 41 Hydraulically Actuated Clutch W4000810 Plug power cord into cigarette lighter 6928 Place bleeder tool into brake fluid con tainer Open the bleed screw and attach the bleeder hose to the bleeder screw on the slave cylinder Clean the reservoir filler cap area and remove the cap Hold the slave cylinder with the bleeder screw at the lowest point and turn the bleed pump on Note 24V motor working at half speed ef 63 T I P d T N y W400081 1 otop the bleed when the fluid is at the minimum level indicated on the side of the reservoir Close the bleeder screw Torque the bleeder screw to 10 Nm 7 ft Ib Note Use DOT 4 fluid only 32 Service Procedures 7 Disconnect the bleeder tool and re move 8 Install clevis pin with new cotter pin W4000870 Install slave cylinder with the two 12 mm socket mounting bolts Be sure t
27. slave cylinder installation ausdezpsskhakndbeas c aU URP p EM REPE MA RI FAM 31 Clutch bleeding procedure rrrrrrrrnnnnsrvvrrnnnnnrennnnnnnnnennnnnnnnsssnnrnnnsnennnn 33 Upper clutch pedal adjustment Ja 34 Lower clutch pedal adjustment ccccccseeeceeeeseeeeeeeeeeceeeeeeeessauaaeees 34 METT SELBE TIG eSak 35 Inhibitor valve splitter adjustment sseeeeeereeeeeee 36 TAS FEV e rm 38 Volvo ITVS SINT ee penducu RU eei n 38 Nonm SEE EE ee TIT 42 Transmission installation oo cece cee eeceeeeeeceeeeeaeeeeeeeeeceeeesseeeeesaeeesaaeees 44 VORBEI JG 44 Non Volvo transmission cccccescccseeeeccseeceeeeecaeeeceueeseusseesausessueeeees 48 Bl RAO en 50 shift linkage installation 121a hr rta there pre En EU ntn A an aha art 51 Group 41 Hydraulically Actuated Clutch About this Service Information General About this Service Information The information and instructions contained in this Service Information pertain to the following components Clutch e Volvo 17 single plate model CLA3S O previously KFD117E e Volvo 15 double plate model CL38D O previously KFD215B e Spicer Easy Pedal 1552 double plate ceramic Note For more information on servicing the Volvo clutches please refer to the Volvo Service Manual 411 600 Clutch Pull Type Volvo Clutch Master Cylinder e Hydraulic master cylinder with plastic reservoir Clutch Slave Cylinder
28. ssion to the jack 2 Roll the transmission under the truck and jack up the transmission 3 Install a new rubber bushing onto the engine transmission nodal mount pins Note Put anti seize on the pin before installing rubber bushing 4 Push the transmission forward and align the input shaft making sure the clutch fork is positioned properly over the release bearing 48 Service Procedures W4000854 Install the transmission mounting bolts and torque them to 95 100 Nm 70 75 ft lb 6 Remove transmission jack 7 Remove engine support W4000807 Install engine mount top half and cross member Torque bolts to 105 20 Nm 78 15 ft lb 5 8 socket torque wrench 15 mm wrench socket 18 mm wrench socket torque wrench Group 41 Hydraulically Actuated Clutch Service Procedures 9 12 W4000812 W4000871 Install gear lever and secure with the 11 16 socket clamp bolt Torque bolt to 70 15 Nm 5 8 wrench 52 11 ft lb temperature sender reverse light sender vehicle speed sensor ECU vehicle speed sender speedometer RA con Install temperature sender 1 and 19 torque to 48 Nm 35 ft Ib Install the air lines that were removed 9 16 socket uan Note Use pipe sealer on threads during transmission removal 13 11 Connect the wire harness to the sen 9 16 socket sors and secure the wires with tie 15 16 wrench wraps 1
29. ters 21 Black Range cylinder 22 Blue Splitter cylinder 5 Install the upper and lower shift boots 12 mm socket into the proper positions Install four 6 extension mounting bolts torque wrench 6 Road test the vehicle to check for proper shift operation and air leaks 52 Service Procedures 53 VOLVO Volvo GM Heavy Truck Volvo GM Heavy Truck Corporation 7825 National Service Road P O Box 26115 Greensboro NC 27402 6115 Volvo GM Canada Heavy Truck Corp 6490 Vipond Drive Mississauga Ontario L5T 1W8 PV776 TSP24581 1 1500 10 96
30. the bottom of the steering column Remove the cover over the lower steering column by removing the plastic rivets W4000819 Note Be careful not to damage the Remove the clutch pedal return spring 13mm deep lower cover when removing to access the two master cylinder swivel mounting bolts ratchet 6 ex tension Note Depress the clutch pedal for easier access to the mounting bolts 26 Group 41 Hydraulically Actuated Clutch Service Procedures Master cylinder installation 1 T4006731 ADEN Install reservoir on the master cylinder 7mm socket Remove the fluid line and remove the 17 mm open and secure with band clamp Torque ratchet master cylinder from the pedal plate end wrench band clamp to 3 Nm 26 in lb assembly 12 mm open end wrench Note Lubricate the mount tube on the Note Remove O ring between the fluid reservoir which connects to the master cylinder and the pedal plate master cylinder s rubber seal before assembly the reservoir is fitted to the master cylinder Use grease p n 8775046 or 8708640 2 Clean the 45 degree angle fitting and 12 mm open install it hand tight on the master cylin end wrench 9 der Use pipe sealant on the fitting Remove 45 degree angle fitting from 12 mm open master cylinder end wrench 10 T4006730 Remove the band clamp holding the 7mm socket reservoir Remove the reservoir by pulling the reservoir out of the rubber seal 27 Group 41 Hydraulical
31. the cotter pin and nut from 19 mm the rod end assembly wrench side cutters 4 Remove the rod end assembly Pull hammer ball down the rod end assembly until rod end is out of control lever Release slowly to release spring tension Dis connect both springs joint separator Group 41 Hydraulically Actuated Clutch 5 Remove the nut from the control yoke at support assembly Lift assembly out 19 mm socket W4000865 Remove the three mounting bolts for the support assembly then remove the assembly 14 mm socket Service Procedures Shift linkage installation 1 W4000848 Install the support assembly with three mounting bolts Torque the two upper mounting bolts to 30 5 Nm 22 4 ft lb Torque the lower mount ing bolt to 48 8 Nm 35 x 6 ft lb 14 mm socket torque wrench W4000866 Install the control assembly and nut 19 mm Connect the springs to the rod assem wrench side bly Torque the control assembly nut cutter 19 mm to 50 10 Nm 37 x 7 ft lb crow s foot torque wrench 51 Group 41 Hydraulically Actuated Clutch W4000847 Position the rod end into the control 19 mm socket lever Install the rod end nut and cot torque wrench ter pin Torque the rod end nut to 40 10 Nm 30 7 ft lb W4000849 Connect the air lines to the gear lever 10 mm open knob Tie wrap the air lines end wrench 18 mm open 1 Purple Supply end wrench 3 Yellow Vent side cut
32. utch Volvo clutch servo installation 1 Position the servo cylinder into place and hand tighten the hydraulic line Note Install a new O ring on the hy draulic line connection W4000867 Install the front and rear clevis pins pliers and secure with cotter pins 3 Tighten the hydraulic line and connect 19mm open the air and vent lines Torque the hy end wrench draulic connector to 45 Nm 33 ft lb 17 mm open and the air line to 24 Nm 18 ft lb end wrench 17 mm crows foot socket torque wrench 4 Bleed the air from the servo and clutch system using the clutch bleed ing procedure 24 Service Procedures Volvo clutch servo adjustment 1 W4000824 Measure the distance A from the 15 mm clutch servo end to the lock nut Ad wrench 19 just to 55 1 5 mm 2 17 0 05 in mm wrench ruler N CAUTION Improper clutch operation If the distance above is too long the clutch may not fully disengage If the distance is too short the clutch may not fully engage W4000824 Measure the distance B between ruler the clevis pin center and the end of the clutch servo If the distance ex ceeds 115 mm 4 5 in re indexed the clutch arm on the cross shaft to adjust Note Only when the clutch arm has been removed is this adjustment nec essary Group 41 Hydraulically Actuated Clutch W4000872 Pre select splitter Press the clutch ruler pedal until just before the splitter shifts
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