IMPACT 4.02.

11 26/04/17

Chassis ID Path
8 926916 4111/Repair//Clutch, replace

Model Identity
FM (4) 134063161

Publish date ID/Operation

12/07/14 41101-2

41101-2Clutch, replace
Illustrations may differ slightly from the actual vehicle being serviced. However, key
components addressed in this information are represented as accurately as possible.

CAUTION
Risk of material damage.
Disconnecting the batteries incorrectly may damage the electrical system.

▶ Follow the instructions carefully in order to disconnect the batteries correctly.

DANGER
Risk of serious injury.
The vehicle can be set in motion if appropriate safety precautions have not been taken.

▶ Set the gear lever in neutral position and apply the parking brake before starting the engine.

Special tools

88800014 88890148 88890149 9990024 9992976

9996857 9996896 9996996

1 Lock the roof spoiler.

2 Move the gear shift lever to the neutral position.

3 Apply the parking brake.

4 Exit the cab. Make sure all the doors are closed.

5 Open the front cover.

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 4.02.11 26/04/17

WARNING
Risk of serious injury.
A cab that is not tilted to the end position constitutes a safety risk.

▶ Always tilt the cab to the end position. Never perform any work under the cab before it has been
tilted to the end position.

CAUTION
Risk of material damage.
Damage may occur to the cab.

▶ Make sure that there is adequate space in front of the vehicle before tilting the cab.

6 Raise the cab.

7 Perform this procedure when the condition below is met.

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 4.02.11 26/04/17

Conditions
● If the vehicle has an alarm.

▶ Set the alarm to service mode.

8 Remove the key from the starter switch (1).

9 Press the button for the warning flashers (2).

10 Press and hold down the warning flasher button (3).

Conditions
● Hold in the button for at least 5 seconds.

Tech data

If the process was successful: The courtesy light and interior light
are off when the door is opened.

11 Wait for at least 30 seconds (4).

12 Remove the cable from the negative terminal (5).

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 4.02.11 26/04/17

Note
The pneumatic system must be depressurised before the hoses are removed.

13 Drain the pneumatic system.

Required material

CONNECTOR 9992976

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 4.02.11 26/04/17

14 Remove the hose clamp.

15 Remove the air bellows.

16 Remove the screw (A).

17 Disconnect the connector.

18 Remove the air filter housing.

Note
Protect the intake from dirt and foreign objects.

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 4.02.11 26/04/17

19 Remove the bolts.

20 Remove the cross member.

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 4.02.11 26/04/17

WARNING
Risk of burn injuries.
Heated components and mechanical parts can cause burns.

▶ Exercise caution when working with heated components. Always use the appropriate protective
equipment.

21 Remove the clamp (2).

22 Remove the clamp (1).

23 Remove the exhaust pipe.

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 4.02.11 26/04/17

24 Remove the bolts.

25 Remove the power transfer 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 4.02.11 26/04/17

26 Remove the sound insulation.

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 4.02.11 26/04/17

27 Disconnect the pipe.

Note
Use circlip pliers.

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 4.02.11 26/04/17

28 Disconnect the pipe.

Note
Use circlip pliers.

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 4.02.11 26/04/17

29 Remove the clamps.

30 Disconnect the connector.

31 Remove the wiring harness.

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 4.02.11 26/04/17

32 Position a pit jack.

33 If necessary install wedges (1 - 2).

34 Install a strap (A).

35 Remove the gearbox tower nuts.

36 Remove the gearbox.

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 4.02.11 26/04/17

37 Position the tool (A).

Required material

CENTERING_DRIFT 9990024

38 Loosen the screws.

39 Loosen the nuts.

Note
Loosen gradually observing the order.

Note
This prevents the distortion of the clutch.

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 4.02.11 26/04/17

40 Install the tools.

Required material

FIXTURE 9996857

RETAINER 9996896

SUPPORT 9996996

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 4.02.11 26/04/17

A FIXTURE 9996857

B RETAINER 9996896

C SUPPORT 9996996

41 Remove the screws.

42 Remove the nuts.

43 Remove the pressure plate.

Tech data

Single disc clutch, weight 38 – 41 kg

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 4.02.11 26/04/17

44 Remove the disc.

45 Remove the tool.

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 4.02.11 26/04/17

46 Check the condition of the flywheel.

Note
Check for cracks or deep grooves.
The surface must be perfectly clean, with no oil, and no grease.
Check the bearing.

47 Install the tool.

Required material

CENTERING_DRIFT 9990024

48 Install the disc.

Note
Observe the position and direction of assembly.

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 4.02.11 26/04/17

Note
The disc and the pressure plate must be replaced together.

49 Install the tools.

Required material

FIXTURE 9996857

RETAINER 9996896

SUPPORT 9996996

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 4.02.11 26/04/17

A FIXTURE 9996857

B RETAINER 9996896

C SUPPORT 9996996

50 Install the pressure plate.

Note
The disc and the pressure plate must be replaced together.

51 Install the nuts.

52 Install the screws.

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 4.02.11 26/04/17

53 Screw in the screws.

54 Screw in the nuts.

Note
Screw in gradually observing the order.

Note
This prevents the distortion of the clutch.

55 Torque tighten the screws.

56 Torque tighten the nuts.

Tightening torque

Clutch, screw, nut 53 ±5 Nm

Required material

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 4.02.11 26/04/17

TORQUE WRENCH 88890148

57 Remove the tool (A).

58 Remove the cap.

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 4.02.11 26/04/17

59 Set up the tool (A).

Required material

ROTATION TOOL 88800014

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 4.02.11 26/04/17

60 Remove the plug.

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 4.02.11 26/04/17

61 Turn the flywheel.

Required material

ROTATION TOOL 88800014

62 Install the gearbox.

63 Install the gearbox tower nuts.

64 Tighten to torque.

Tightening torque

Anchorage bolts for the gearbox to the flywheel housing 92 ±8 Nm

Required material

TORQUE WRENCH 88890149

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 4.02.11 26/04/17

65 Remove the strap (A).

66 Remove the pit jack.

67 Remove the wedges (1 - 2).

68 Install the gasket.

Note
Use a new part.

69 Install the plug.

70 Tighten to torque.

Tightening torque

Clutch solenoid vent plug 6.5 ±0.5 Nm

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 4.02.11 26/04/17

Required material

TORQUE WRENCH 88890148

71 Install the cap.

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 4.02.11 26/04/17

72 Connect the connector.

73 Install the cable clamps.

Note
Use new parts.

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 4.02.11 26/04/17

74 Connect the pipe.

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 4.02.11 26/04/17

75 Connect the pipe.

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 4.02.11 26/04/17

76 Install the exhaust pipe.

77 Install the clamps.

78 Tighten the clamp (2).

79 Tighten the clamp (1).

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 4.02.11 26/04/17

80 Install the power transfer shaft.

81 Install the bolts.

Note
Use new parts.

82 Tighten to torque.

Conditions
● Bolt M14

Tightening torque

Transmission, bolts Bolt M14

160 Nm  ±20 %
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
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IMPACT 4.02.11 26/04/17

Conditions
● Bolt M12

Tightening torque

Transmission, bolts Bolt M12

100 Nm  ±20 %

Conditions
● Bolt M10

Tightening torque

Transmission, bolts Bolt M10

60 Nm  ±20 %

Required material

TORQUE WRENCH 88890149

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 4.02.11 26/04/17

83 Install the cross member.

84 Install the bolts.

85 Tighten the bolts.

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 4.02.11 26/04/17

86 Install the air filter housing.

87 Install the screw (A).

88 Connect the sensor.

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 4.02.11 26/04/17

89 Install the air bellows.

90 Install the air hose.

91 Tighten the hose clamp.

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
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IMPACT 4.02.11 26/04/17

92 Connect the cable to the negative terminal (1).

93 Insert the key (2).

94 Perform this procedure when the condition below is met.

Conditions
● If the vehicle has an alarm.

▶ Deactivate service mode.

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 4.02.11 26/04/17

WARNING
Risk of serious injury.
A cab that is not tilted to the end position constitutes a safety risk.

▶ Always tilt the cab to the end position. Never perform any work under the cab before it has been
tilted to the end position.

95 Lower the cab.

96 Lower the front cover.

97 Connect the nipple (A).

Required material

CONNECTOR 9992976
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
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IMPACT 4.02.11 26/04/17

98 Fill with air.

99 Connect the diagnostic tool (Volvo Tech Tool).

100 Calibrate the clutch as instructed in the diagnostic tool (Volvo Tech Tool).

101 Disconnect the diagnostic tool (Volvo Tech Tool).

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
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IMPACT 4.02.11 26/04/17

102 Install the exhaust hose on the exhaust pipe.

103 Apply the parking brake.

104 Move the gear shift lever to the neutral position.

105 Start the engine (III).

106 Perform leakage control of the repair.

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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