Service Bulletin

Volvo Trucks North America

Greensboro, NC USA Trucks
Date Group No. Release Page
This service bulletin replaces bulletins 465-01
and 465-02 “Input Shaft Sealing Ring, 4.2010 465 01 1(13)
Replacement” dated 6.2007.
Input Shaft Sealing Ring, Replacement
I-Shift Transmission

Input Shaft Sealing Ring, Replacement

W4002883

Note: Information is subject to change without notice.

Illustrations are used for reference only and may differ slightly from the actual vehicle
being serviced. However, key components addressed in this information are represented
as accurately as possible.

• “Input Shaft Sealing Ring, Replacement”, page 2

PV776-88956918 USA40104
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 2(13)

4658-03-02-02
Input Shaft Sealing Ring, Replacement
You must read and understand the precautions and
guidelines in Service Information, group 4, “General
Safety Practices, Transmission” before performing this
procedure. If you are not properly trained and certified
in this procedure, ask your supervisor for training before
you perform it.

DANGER
Do not attempt to repair or service this vehicle without
having sufficient training, the correct service literature
and the proper tools. Failure to follow this could make
the vehicle unsafe and lead to serious personal injury or
death.

DANGER
Before beginning any work on any part of the air system,
be certain that the air pressure has been released. Failure
to do so may cause a component to violently separate,
which can result in serious personal injury.

Special tools: 88800005, 85108826

1
1
Apply the parking brake.
2
2
Disconnect power to the vehicle by removing the batteries
negative cable.
3
3
Drain the air system.
4
4
Raise the vehicle and support with jack stands.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 3(13)

5
5
Disconnect the transmission oil cooler hoses from the
filter housing.

85108826

W4002890

6
6
Remove the drive shaft.

Note: Remove the universal joint caps and the bolts

holding the intermediate bearing to the support bracket
(if equipped).

Note: Mark the position of the bolts on the bracket so

that the intermediate bearing is installed in exactly the
same position as before. Position the shaft aside.

T4018155

7
7
Disconnect the air supply hose at the rear of the
transmission.

W4002940

8
8
Remove the tie straps securing the wiring harness to the
transmission.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 4(13)

9
9
Disconnect the electrical harness at the control housing,
speed sensor, and the two chassis connectors.

Note: Position the harness out of the way.

W4002941

10
10
Remove the cab engine cover.
11
11
Remove the transmission-to-engine mounting bolts along
the bottom and sides of the clutch housing.

Note: Do not remove the top four transmission-to-engine

mounting bolts at this time.
12
12
Position the transmission jack and secure the
transmission to it.
13
13
Remove the bolts securing the battery cables to the
brackets on the top of the clutch housing.
14
14
Remove the top four transmission-to-engine mounting
bolts.
15
15
Carefully pull the transmission back until the input shaft
clears the pressure plate. Lower the transmission and
pull it out from under the vehicle.

Note: While lowering the transmission, periodically check

around it to assure nothing is caught or hung up on it
such as wiring or air hoses.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 5(13)

16
16

DANGER
The Clutch Valve Unit contains air under high pressure.
Do not remove the drain plug entirely because doing
so may allow the plug to quickly and forcefully and
become a projectile. Leave the drain plug slightly
cracked to allow air pressure to be released. Failure to
do so may result in serious personal injury.

Remove the service plug located on top of the clutch

W4002879
valve to ensure that no air remains in the system.

17
17
Carefully remove the tie straps for the wiring harness,
and the air hose to the clutch cylinder.

T4021344
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 6(13)

18
18

Remove the clutch valve mounting bolts.

W4002923

19
19
Disconnect the clutch position sensor wiring and position
the clutch valve aside.

W4002924
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 7(13)

20
20
Remove the clip holding the air hose in the clutch
cylinder. Disconnect the air hose from the clutch cylinder.
Remove the clutch cylinder mounting bolts and then the
clutch cylinder.

T4020990

21
21
Using an appropriate seal removal tool, remove the input
shaft seal.

W4002954

22
22
Clean and inspect the contact surfaces for the seal.
23
23
Apply fresh transmission oil on the new sealing lip.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 8(13)

24
24
Install the new input shaft seal.

T4021446

25
25
Clean and inspect the supply hose connections. Replace
the supply hose O-rings. If there is any damage to the
hose or connections, replace the damaged part.
26
26
Position the clutch cylinder. Install and torque the
mounting bolts.

45±5 Nm (33±4 ft-lb)

27
27
Connect the air hose to the clutch cylinder and install the
locking clip.

T4021345
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 9(13)

28
28
Check that the sealing surface on the clutch valve
assembly is clean. Inspect the clutch valve seal and
replace as needed.
29
29
Connect the clutch position sensor wiring to the clutch
valve.

W4002924

30
30
Install and torque the clutch valve mounting bolts.

20±3 Nm (15±2 ft-lb)

W4002923
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 10(13)

31
31
Secure the wiring harness and air hose in position with
new tie straps.

T4021344

32
32
To aid transmission installation, remove the service plug
on the clutch control valve assembly and push the piston
all the way into the clutch cylinder. While holding the
piston in, install the plug and torque.

Note: Failure to perform this step will hamper installation.

The transmission will be installed under clutch cylinder
spring pressure and will fail to freely slide forward into
place against the engine mating surface.

7±2 Nm (5±1 ft-lb)

T4021203

33
33
Carefully install the transmission and align it to the
engine. Loosely install two upper and two lower
transmission-to-engine mounting bolts to hold the
transmission in place.

Note: The use of an assistant may be necessary to aid

installation.

Note: Rotate the input shaft to align the clutch splines.

Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 11(13)

34
34
Install the remaining transmission-to-engine mounting
bolts. Torque the bolts and remove the transmission jack.

Note: To aid access, install and tighten the mounting

bolts on the top of the clutch housing first. Remove the
transmission jack and install the remaining mounting
bolts.

92±8 Nm (68±6 ft-lb)

35
35
Position the battery cables and install their mounting
bolts.
36
36
Install the cab engine cover.
37
37
Position the electrical harness and reconnect the control
housing, speed sensor, and the two chassis connectors.

W4002941

38
38
Install new tie straps to securing the wiring harness to
the transmission.
39
39
Connect the air supply hose at the rear of the
transmission.

W4002940
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 12(13)

40
40
Connect the transmission oil cooler hoses to the filter
housing.

W4002894

41
41
Install the drive shaft, the universal joint caps and the
bolts holding the intermediate bearing to the support
bracket (if equipped).

Note: Install the universal joint caps and the bolts

holding the intermediate bearing to the support bracket
(if equipped).

Note: It is important to center the rubber insulator in the

U-bracket correctly.

Intermediate Bearing – 175±30 Nm (129±22 ft-lb)

T4018155 Universal Joint Caps – 166±10 Nm (122±7 ft-lb)

42
42
Remove the supporting jack stands and lower the vehicle.
43
43
Pressurize the air system and check for leaks.
44
44
Restore power to the vehicle by connecting the batteries
negative cable.
Volvo Trucks North America Date Group No. Release Page
Service Bulletin 4.2010 465 01 13(13)

45
45
Check and fill the transmission with approved
transmission oil.

T4021684