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6.
Unscrew
the nut for the rear engine mounting and
remove
the
cross-member. Disconn,ect the brackets
for
th
e ex ha ust pipe
and the 'rear
engin
e
mounting.
Remove
,
t he
spee,dome,
t
,e
r
cah le from
lhe
gearbox.
Release
the oi
l
~i
"
er
pipe.
7. Lower the eng
in
e about 20 mm (.8"
). Observe
due
care
with
t he
battery
lead. If any tensions arise,
re lease t.he lead clamp.
8.
Disconn
ect t he erleotric
ca
b les from the
sta'
r ter in-
hibitor.
Unscrew
t he S'crews for t he starter in
hibi-
tor. Place a jack w it
h
fixture SYO 2746 under the
gea
rb
ox. See Fig. 4-77. Unsorew t he
atta'
c
h,
i n
g bo lts
f
o
r th
e co nverter cas ing.
PlIII
the gearbox
back-
wards a,nd release t he guide pin on the converter
at
t he same t ime. Lower and remove the
gearbox.
DIS,
M ANTLlNG
A
s
a general
r
ul
e it is advisab le on ly to ,dismantie
thos
e
compon
ents requ
irin
g atrfent io
n
as indicated
by
road-testing or f
a
ult-tracin
g prooed ure.
Prior to the
remova'l
of
any com
p
on
e,nts,
t
he outsid
e
of
the gearbox must be thoroughly washed down with
white
spi,rit. A
high
standard of c1eanlines
s
is required
when handling
or storing
compone,nts.
When
dirsmantling, the gearbox should be
inverted
and
placed
-on the bench cradle as shown
in
Fig
.
4-78,
Fig.
4-79.
Oil tubes
A
,
Front
serv
o releas
e
B.
Front
servo
.
application
C.
Rear clutch
D
.
Rear
serv
o
VOLVO
le3835
and special tools used as shown in the service tool
list.
Treat the v,arious components with great care,
particu
larly
light-a llroy
parts. When
,
t he gearrbox
is to
be
completely
dismantled, follow the procedure
below.
l.
If
the converter
housing is
attached to the gear-
box,
remove the
six
bo lts and withdraw the
con-
verter housing.
2. Unscrew t he
"W'
e ldg l·ok" screw for t he drive f lange
on t
he output shaft.
Pu,I,1
o ut t he drive
f1.a
nge and
catch the
%"
p la irn was her. Loose
n
and w ithdraw
t he rea'r ho using.
~emo
v
e
t he speedo meter gear.
3.
Un screw
t he bo lts for t he oi
l
pan and remove
t
hi
s. Lever o ut t he o
il
tubes
carefull
yas shown in
Fig
. 4-79.
THE
VALVE
BODlES ASSEMBLY
Work on t he whO'le assemb ly sho uld pr,eferab ly be
carried out in a diesel test-room or in a room w it
h
equ
a
l
sta ndal1ds of clean
Hn
ess.
4. Discon nect t he downshift
v
a'lve cah le from t he
down shift
valve
cam. Unscrew the thr,ee screw
s
which retain th
e
v
a lve
bodies assembly to the
gearbox housing, see Fig
.
4-80.
Lift
,
t h
e v
alve
bodies assembly st rraight
up
'so th at it
're,leases
from
the oil tube
s
at the front
end.
5.
Unscrrew the
t
wo screws for the bracket of
t
he
downshift
vallve
cam.
6. Remove the two strainers for the
fron'
t and rear
pump re
specNvely.
7.
Unsorew from above the screws which reta
in t
he
upper
va
lve
body.
Turn the
varlve
bodies assembly
round and unscrew th
e
other si
x
screws
f
rom un-
derneath.
8.
UnS'crew
the eight
'
s crews which ret
ain
the oil tube
collrector.
9.
Unscrew
the four screws
which rerra,in
the gover
..
nor I,ine
plate.
N
'
o te that two screws are
und
er one
of
the straine'rs.
10.
Remove
the separating plate and .then the check
valves for the converter and front and rear pumps,
see Fig. 4-82. Withdraw the
manual
oonkol
valve,
see "A", Fig
.
4-83.
11.
Remove
the stops for the throtHe
valve
and
,
t he
return
spring. Then withdraw -the
downshift valve,
spring and
throttle valve,
see "B", Fig.
4-83.
12.
Remove the
dowel pin which retains the
plug
for
the
modulator
valve. Then rem
ove
the plug,
vdve,
plunger
ond spring.
13.
Remove
,
t he
stop for
the
servo
orifice
oontrol valve
and
then
the spring
and
valve
.
4
:
33
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