IMPACT 4.00.51.

00-SNAPSHOT 30/01/16

Chassis ID Path
431/Description, Design and function//Main components

Model Identity
131346138

Publish date ID/Operation

18/09/12

Main components

Input shaft and main shaft

The input shaft (1) is manufactured as a single part and is supported on the clutch housing by means of a tapered roller
bearing.

The main shaft (2) is supported on the input shaft and the rear wall of the basic housing. All of the gears turn freely on
the shaft, supported on needle bearings.

The main shaft contains a central hole for the distribution of lubricating oil to all of the support points on the shaft and
gears.

1. Input shaft

2. Main shaft

3. Countershaft

4. Planetary gears

5. Reverse gear shaft

6. Oil pump

Synchronisation

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.00.51.00-SNAPSHOT 30/01/16

Both the basic gearbox synchronisers and the range gear synchronisers are made of steel with separate coupling
rings.

1. Synchroniser rings

2. Detent with spring, pin and retainer

3. Coupling rings

4. Coupling body

5. Coupling sleeve

Operation
In the neutral position, the coupling sleeve (5) is held against the coupling body (4) with the help of the detents (2),
which are subject to the force of a spring. The tapered surfaces of the synchroniser rings (1) and the coupling rings (3)
are separated by a film of oil.

When the driver activates the gear lever, the coupling sleeve (5) moves towards the desired gear. This movement
brings the synchroniser ring (1) into contact with the coupling rings (3). Owing to the friction between the tapered
surfaces of the synchroniser ring and the coupling ring, the synchronising ring turns less in relation to the coupling
sleeve, preventing the sleeve from moving continually.

When the friction between the tapered surfaces makes the moving parts turn at the same speed, the friction stops.

The pressure exerted by the gear lever forces the synchroniser ring to turn in the opposite direction until the coupling
sleeve can continue its interrupted rotational movement until it fully engages with the coupling ring.

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.00.51.00-SNAPSHOT 30/01/16

A. Neutral position

B. Synchronisation

C. Gear engaged

Countershaft
The countershaft is supported on the clutch housing and the rear wall of the basic housing by means of tapered roller
bearings. The two front gears are pressed onto the shaft while the other gears form an integral part of the shaft.

Reverse gear shaft

The reverse gear shaft is supported in a spacer bushing on the rear wall of the basic housing and on a bracket which is
fused to the side wall of the basic housing. The oil pump drive shaft is supported inside the reverse gear shaft. Both the
oil pump drive shaft and the reverse gear are supported on the reverse gear shaft by means of needle bearings.

When reverse gear is engaged, the reverse gear becomes attached to the main shaft, making the reverse gear work
between the main shaft and the countershaft. In this way, the main shaft can turn in the opposite direction to that in
which the input shaft rotates.

1. Spacer sleeve

2. Bracket

3. Reverse gear

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.00.51.00-SNAPSHOT 30/01/16

4. Needle bearing, reverse gear

5. Oil pump

6. Oil pump drive shaft

7. Needle bearing, oil pump drive shaft

Range gear, planetary gears and output shaft

The planetary gear carrier and the output shaft are balanced and installed with a high degree of interference during the
manufacturing process. As such, they must never be separated from each other. The rear gear on the main shaft (A) is
the sun gear which forms part of the planetary gear reduction assembly (B). The output shaft is supported on a ball
bearing on the rear wall of the range gear housing (version without retarder), or on the retarder bearing (version with
retarder).

A. Sun gear

B. Planetary gear reduction assembly

Functioning of the planetary gears

The gearchange fork of the planetary gears is activated by the range gear control cylinder, which is controlled
pneumatically.

In the high range gear position, the ring gear is disengaged, allowing the output shaft to turn at the same speed as the
main shaft.

High range gear

Ring gear disengaged (1:1)

In the low range gear position, the rotation of the output shaft is 3.75 times slower than the rotation of the main shaft.
Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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IMPACT 4.00.51.00-SNAPSHOT 30/01/16

Note: Depending on the gearbox version, the number of planetary gears may vary.

Low range gear

Locked ring gear (3.75:1)

1. Gear ring

2. Planetary gear

3. Sun gear

Copyright to this documentation belongs to the Volvo Group. No reproduction, copying, change, amendment or other similar disposal is entitled without prior written consent by
the Volvo Group
The information contained herein is current at the time of its original distribution, but is subject to change. The reader is advised that printed copies are uncontrolled.

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