Workshop Manual Transmission of HT200 SDLG Volvo

VOLVO HT200
Foreword
This Service Manual deals with the design, working principles and repair instructions for transmissions HT200
and HT201.
The instructions apply assuming that the transmission is removed from the machine or exposed in the machine.
The necessary approach operations can be found in the Service Manual for the machine type concerned.
The work procedures are based on the use of special(999)-tools, tools which can be made in your own
workshop(E-tools)and standard tools generally available on the marker.
All lifting devices such as strops, slings, ratchet blocks etc., must comply with appropriate National Regulations
for such equipment.
VME accept no responsibility if any lifting devices, tools or working methods other than those described in this
publication are used.
This warning symbol will appear at various points in this manual in conjunction with warning
statements. Its appearance means WARNING! BE ALERT! YOUR SAFETY IS INVOLVED!
The information and data given in this manual are valid at the time of publication. It is our policy
to constantly strive to improve our products. The right therefore is reserved to make changes in design and
improvements whenever it is believed the efficiency of the product will be improved, without incurring any
obligation to incorporate such improvements in any product which has been shipped or is in service.
Under our policy of continual product improvement, VME reserve the right to change specifications and
equipment without prior notice.
HT200 HT201
VME
VME
VOLVO HT200
Contents
FOREWORD......................................................................................................................... 1
SPECIFICATIONS................................................................................................................ 4
STANDARD TIGHTENING TORQUES............................................................................. 8
DESCRIPTION..................................................................................................................... 10
GENERAL REPAIR INSTRUCTIONS................................................................................ 11
REPAIR INSTRUCTIONS................................................................................................... 16
Transmission, reconditioning................................................................................................ 16
Torque converter, rebuilding................................................................................................. 31
Torque converter, reconditioning........................................................................................... 32
Oil pump and turbine shaft bearing, reconditioning.............................................................. 42
Damping valve, reconditioning............................................................................................. 45
Gear selector valve, reconditioning....................................................................................... 46
Lubricating oil valve, reconditioning.....................................................................................52
Power take-off, reconditioning.............................................................................................. 52
Forward and first clutches, dismantling and assembling....................................................... 54
Reverse and second clutches, dismantling and assembling................................................... 71
Third and fourth clutches, dismantling and assembling........................................................ 85
Transmission, assembling...................................................................................................... 103
Piston unit for parking brake HT200 ser.no.-2790, reconditioning....................................... 111
Piston unit for parking brake HT200 ser.no.2791-and HT201,reconditioning...................... 114
DRAWINGS OF E-TOOLS WHICH CAN BE MADE IN YOUR OWN WORKSHOP.... 130
DRAWINGS
Clutch shaft, forward-first, HT200........................................................................................ 132
Clutch shaft, reverse-second, HT200.................................................................................... 134
Clutch shaft, third-fourth, HT200, transmission ser.no.-2205............................................... 136
Clutch shaft, third-fourth, HT200, transmission ser.no.2206-............................................... 138
Clutch shaft, forward-first, HT201........................................................................................ 140
Clutch shaft, reverse-second, HT201..................................................................................... 142
Clutch shaft, third-fourth,HT201........................................................................................... 144
Torque converter.................................................................................................................... 146
Torque converter.................................................................................................................... 147
VOLVO HT200
....................................................................................................................................... 1
....................................................................................................................................... 5
....................................................................................................................... 9
....................................................................................................................................... 10
....................................................................................................................... 11
............................................................................................................................... 16
....................................................................................................................... 16
............................................................................................................... 31
....................................................................................................................... 32
....................................................................................................... 42
....................................................................................................................... 45
............................................................................................................... 46
....................................................................................................................... 52
....................................................................................................................... 52
....................................................................................... 54
....................................................................................... 71
....................................................................................... 85
....................................................................................................................... 103
HT200 -2790 ................................................................................. 111
HT200 2791- HT201 ................................................................114
E-...................................................................................... 130
HT200........................................................................................ 132
HT200........................................................................................ 134
HT200 -2205...................................................................... 136
HT200 2206-..................................................................... 138
HT201........................................................................................ 140
HT201........................................................................................ 142
HT201........................................................................................ 144
................................................................................................................................... 146
................................................................................................................................... 147
VOLVO HT200
Specifications
WEIGHTS
Transmission with dropbox,
Power take-off(2 pcs)and torque converter approx.
Torque converter, approx.
840kg
110kg
1852Ib
243Ib
TIGHTENING TORQUES
Torque converter-transmission housing
Power take-off
Oil distributor
Suction strainer
Cover for suction strainer
Transmission oil pump
Torque converter attaching bolts
Drive flange nut
Cover for shafts
Brake housing-cover
Induction sender unit
Gear selector valve
Lubricating oil valve
Washer, turbine shaft
Gear selector valve sleeve, solenoid ASCO
Bolt ASCO
Sleeve, solenoid Skinner
Bolt skinner
Upper shaft in dropbox:3 pcs attaching bolts 1st tightening
Stop screws, 3 pcs, first tightening
Attaching bolts,3 pcs final tightening
Nm
80
45
25
25
20
45
45
600
45
45
45
25
25
40
25
5
12
3
40
20
80
kgf m
8
4.5
2.5
2.5
2.0
4.5
4.5
60
4.5
4.5
4.5
2.5
2.5
4.0
2.5
0.5
1.2
0.3
4
2
8
Ibf ft
59
33
18
18
15
33
33
443
33
33
33
18
18
30
18
4
9
2
30
15
59
VOLVO HT200
, (2 )
, .
840kg
110kg
1852Ib
243Ib
Nm
80
45
25
25
20
45
45
600
45
45
45
25
25
40
25
5
12
3
40
20
80
,
ASCO
ASCO
, Skinner
skinner
:3
3
3
kgf m
8
4.5
2.5
2.5
2.0
4.5
4.5
60
4.5
4.5
4.5
2.5
2.5
4.0
2.5
0.5
1.2
0.3
4
2
8
Ibf ft
59
33
18
18
15
33
33
443
33
33
33
18
18
30
18
4
9
2
30
15
59
VOLVO HT200
TRANSMISSION
Make
Type
Designation
Clutch drum, end float
Forward
First
Reverse
Third
Fourth
Disc clearance
Forward clutch
First clutch
Reverse clutch
Second clutch
Third clutch
Fourth clutch
Return springs, first, second and third, loaded length,
pressing force 944-1076N(212-242Ibf)
Return springs, forward and reverse, loaded length,
pressing force 828-1076N(186-242ibf)
Return springs, fourth, loaded length
pressing force 927-1057N(208-237Ibf)
Shaft, end float
Clutch shaft, forward-first
Intermediate gear, preload
Output shaft, preload
Torque converter
Make
Type
Gear selector valve
Spring for main pressure, (HT200)length
at a load of 387-427N(87-96Ibf)
Colour marking
Spring for main pressure, (HT201)length
at a load of 430.6-462.6N(97-104Ibf)
Colour marking
Volvo BM
Hydro-mechanical
HT200
HT201
0.1-0.7mm
0.2-1.0mm
0.2-1.5mm
0.4-1.3mm
0.5-1.5mm
0.004-0.028in
0.008-0.039in
0.008-0.059in
0.016-0.051in
0.020-0.059in
1.9-5.3mm
1.7-5.0mm
1.9-5.3mm
1.7-5.0mm
1.3-4.9mm
1.2-4.0mm
0.075-0.209in
0.067-0.197in
0.075-0.197in
0.067-0.197in
0.051-0.193in
0.047-0.157in
44mm
1.732in
49mm
1.929in
34mm
1.339in
0.15-0.22mm
0.03-0.08mm
0.03-0.08mm
0.006-0.009 in
0.001-0.003in
0.001-0.003in
Rockford-division
single-stage
53.8mm
yellow
2.118in
53.8mm
blue
2.118in
VOLVO HT200
,,,,
944-1076N(212-242Ibf)
,,,
828-1076N(186-242Ibf)
,,
927-1057N(208-237Ibf)
,
,-
,
,
, (HT200)
387-427N(87-96Ibf)
, (HT201)
430.6-462.6N(97-104Ibf)
Volvo BM
HT200
HT201
0.1-0.7mm
0.2-1.0mm
0.2-1.5mm
0.4-1.3mm
0.5-1.5mm
0.004-0.028in
0.008-0.039in
0.008-0.059in
0.016-0.051in
0.020-0.059in
1.9-5.3mm
1.7-5.0mm
1.9-5.3mm
1.7-5.0mm
1.3-4.9mm
1.2-4.0mm
0.075-0.209in
0.067-0.197in
0.075-0.197in
0.067-0.197in
0.051-0.193in
0.047-0.157in
44mm
1.732in
49mm
1.929in
34mm
1.339in
0.15-0.22mm
0.03-0.08mm
0.03-0.08mm
0.006-0.009 in
0.001-0.003in
0.001-0.003in
Rockford-division
53.8mm
2.118in
53.8mm
2.118in
VOLVO HT200
VOLVO STANDARD TIGHTENING TORQUES
The tightening torques in the following tables apply to bolts with a tensile strength of 8.8.The table are to be
considered as a general instruction for the tightening torque of nuts and bolts when no other torque is stated.
N.B. For flanged bolts type U6FS the values should be increased by 10%.
Nuts and bolts should be cleaned and lubricated with oil.
Metric coarse and fine threads
Thread
Nm
M6
M8
M10
M12
M14
M16
M20
M24
10 f
24
48
85
140
220
430
740
Kgf m
2
5
10
18
25
45
85
150
1.0 f
2.4
4.8
8.5
14.0
22.0
43.0
74.0
Ibf ft
0.2
0.5
1.0
1.8
2.5
4.5
8.5
15.0
7.4 f
18
35
63
103
160
320
550
1.5
3.5
7.4
13
18
33
63
110
UNC threads
Thread
Nm
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
9 f
18
33
54
80
120
170
300
485
725
2
4
8
14
20
30
40
70
115
175
Kgf m
Ibf ft
0.9 f 0.2
1.8
0.4
3.3
0.8
5.4
1.4
8.0
2.0
12.0
3.0
17.0
4.0
30.0
7.0
48.5
11.5
72.5
17.5
6.6 f
13
24
40
59
89
130
220
360
530
1.5
3.0
5.9
10
15
22
30
52
85
130
UNF threads
Thread
Nm
Kgf m
Ibf ft
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
10 f 3
22
5
40
10
63
18
98
23
145
35
200
50
355
85
565
135
800
200
1.0 f 0.3
2.2
0.5
4.0
1.0
6.3
1.8
9.8
2.3
14.5
3.5
20.0
5.0
35.5
8.5
56.5
13.5
80.0
20.0
7.4 f 2.2
16
3.7
30
7.4
46
13
72
17
110
26
150
37
260
63
420
100
590
150
VOLVO HT200
8.8
U6FS 10%
Nm
M6
M8
M10
M12
M14
M16
M20
M24
10 f
24
48
85
140
220
430
740
Kgf m
2
5
10
18
25
45
85
150
1.0 f
2.4
4.8
8.5
14.0
22.0
43.0
74.0
Ibf ft
0.2
0.5
1.0
1.8
2.5
4.5
8.5
15.0
7.4 f
18
35
63
103
160
320
550
1.5
3.5
7.4
13
18
33
63
110
Nm
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
10 f
19
34
55
81
121
171
301
486
725
2
4
8
14
20
30
40
70
115
175
Kgf m
Ibf ft
0.9 f 0.2
1.8
0.4
3.3
0.8
5.4
1.4
8.0
2.0
12.0
3.0
17.0
4.0
30.0
7.0
48.5
11.5
72.5
17.5
6.6 f 1.5
13
3.0
24
5.9
40
10
59
15
89
22
130
30
220
52
360
85
530
130
Nm
Kgf m
Ibf ft
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
10 f 3
22
5
40
10
63
18
98
23
145
35
200
50
355
85
565
135
800
200
1.0 f 0.3
2.2
0.5
4.0
1.0
6.3
1.8
9.8
2.3
14.5
3.5
20.0
5.0
35.5
8.5
56.5
13.5
80.0
20.0
7.4 f 2.2
16
3.7
30
7.4
46
13
72
17
110
26
150
37
260
63
420
100
590
150
VOLVO HT200
Description
Transmissions HT200 and HT201 are hydro-mechanical, four-speed, power shift
transmissions with torque converter, cylindrical spur gears with counter-rotating shafts and
hydraulically actuated clutches.
The transmission consists of three main parts.
A front part with torque converter, transmission oil pump and power take-off.
A centre part with cylindrical spur gears, hydraulic clutches and control valves.
A rear part with dropbox and parking brake.
The power from the engine to the road wheels is transferred hydraulically and
mechanically through the transmission. The hydraulic transfer of power takes place in the
torque converter which in addition to transferring the torque also multiplies it. The
mechanical transfer of power is done by gear wheels which are in constant mesh. The
gears on the clutch shafts rotate freely but are locked when a speed gear is engaged.
There are three clutch shafts transferring the power and they are: one for forward and first
speed gear, one for reverse and second speed gear and a third shaft for the third and fourth
speed gears.
The gear changing is by electro-hydraulic means. When a gear is selected, one or more of
the gear selector valve solenoids are activated which actuate the gear selector valve spools,
which in turn control the oil flow to the clutch shafts. The gear selector valve is fitted by
the transmission oil filter and it consists of valve housing, six valve spools and five
solenoids. One of the spools acts as a pressure control valve and it differs from the other
spool which are alike and interchangeable. The spools, which on the hydraulic diagram are
named S2, S3, S4and S5, are gear selector spools. Neutral and drive is selected with spool
S1. The sixth spool controls the main pressure. The gear selector spools have two positions.
They are kept in the resting position by a spring and caused to move to the other position
by pressure differences controlled by the solenoids.
In order to obtain the desired gear, electric current is required at one or more of the
solenoids, which, in their turn actuate the valve spools. The neutral and forward/reverse
drive spool can also be actuated mechanically, in the case of loss of electric power, by
means of two adjusting screws. In order to prevent accidents, if there should be loss of
current to one or more of the solenoids while operating, neutral or a higher gear will be
automatically selected. The only exception is when operating in the fourth speed, shifting
to the third speed will take place. As the down shift is only one step, the slowing-down of
the machine will not be too sudden.
A special valve(damping valve)is fitted on the outside of the gear selector valve. This
damping valve controls the application for the forward and reverse clutches, giving the
shifting between forward and reverse correctly balanced characteristics.
HT200 HT201
10
VOLVO HT200
1 2
3 4
6 5
S2S3S4S5
S1 6
Transmission, HT 200/201
1 Torque converter
2 Lubricating oil valve
3 Parking brake housing
HT 200/201
1
2
3
11
VOLVO HT200
Transmission, HT 200/201
1 Oil filter
2 Damping valve
3 Gear selector valve
4 End coverforward-firstreverse-second, obscured
5 End cover, third-fourth
6 Draining of gear selector valve, only HT 201
or the rebuilt version of HT 200
HT 200/201
1
2
3
4 --
5 -
6 HT201
HT200
NEUTRAL POSITION
The pumps P draw oil from tank N through strainer O. The flow from pump P2 is forced through filter S and on
through line F to pressure-limiting valve U, which is a valve spool built into the gear selector valve.
From the pressure-limiting valve the oil is conducted to the different gear selector spools. All spools are in the
resting position.
The valve spool L(neutral and drive spool)blocks the oil flow to spool H(forward and reverse spool). The spool
M(high and low spool)allows flow of oil through duct V to spool K(controlling the third and fourth speed
gears)which in this position conducts the oil to the third gear in clutch G, which thus becomes engaged. Because
the neutral and drive spool is in the resting position and prevents oil flow to the forward and reverse spool, no
transmission of power takes place.
The valve spool J(controls the gears for the first and second speeds)does in this position not obtain any oil from
valve spool M.
When the main pressure has been built up, the spool in valve U moves to the open position and lets the oil through.
12
VOLVO HT200
This flow joins the flow pump P1 and is conducted through line X, with its safety valve AA protecting the torque
converter, to torque convert A and through the same to the cooling circuit which thus controls the pressure in the
torque converter.
If the temperature is so high that the oil needs cooling, the thermostat directs the flow to cooler T. At lower
temperatures the cooler is by-passed, and the flow is directed to the lubricating circuit where valve C limits the
lubricating oil pressure. Through line Y the lubricating oil is supplied to all clutches which then are both cooled
and lubricated.
The superfluous oil from the lubricating oil valve is conducted by to the pump.
Symbol diagram, neutral position,
HT 200 and 201
A
Torque converter
C
F
Connecting line, filter-gear selector valve
G
Third clutch
H
Forward and reverse gear shift spool
I
Thermostat
J
First and second gear shift spool
K
Third and fourth gear shift spool
L
Neutral and drive gear shift spool
M
High and low gear shift spool
N
Oil sump
O
Strainer
P
Pump
R1
Reverse damping valve
R2
Forward damping valve
S
Filter
T
Oil cooler
U
Pressure-limiting valve
V Pressure duct
Y
Lubrication ling
X Line to torque converter
AA Torque converter safety valve
P N O P2 S F U U
L H
M
V K 3 4 G
J 1 2 M
U P1
X AA A
T
C Y
13
VOLVO HT200

A
F
-
G
R1
R2
AA
Symbol diagram, neutral position HT200, ser. no.-2003 HT200-2003

For ser. No. 2004-. See the inset damping valves 2004-
14
VOLVO HT200
Symbol diagram, neutral position HT201
HT201
Flow diagram, neutral position. HT200 ser.no.-2003

For ser.no.2004-,see the inset damping valves
A
Torque converter
C
D
Forward and first clutches
E
Reverse and second clutches
F
Connecting line, filter-gear selector valve
G
Third and fourth clutches
H
Forward and reverse gear shift spool
I
Thermostat
J
First and second gear shift spool
K
Third and fourth gear shift spool
L
Neutral and drive gear shift spool
M
High and low gear shift spool
N
Oil sump
O
Strainer
P
Pump
R1
Reverse damping valve
HT200 -2003
2004-
A
F
-
G
R1
15
VOLVO HT200
R2
S
T
U
V
X
Y
AA
Forward damping valve

Filter
Oil cooler
Pressure-limiting valve
Pressure line
Line to torque converter
Lubrication line
Torque converter safety valve
R2
S
T
U
V
X
Y
AA
=
=
=
=
Colour key:
Red=Clutch pressure
Blue=Torque converter pressure
Yellow=Lubricating oil pressure
Green=Atmospheric pressure
Repair Instructions
TRANSMISSION, RECONDITIONING
Op.no. 43771
Tools:
999 2628
999 3131
999 3387
999 3517
999 3538
999 3577
999 3582
999 3586
999 3590A
999 3598
999 3599
999 3616
999 3659
999 3712
999 3713
999 3716
6 999 001
6 999 002
6 999 010
6 999 060
6 999 070
6 999 080
6 999 088
6 999 090
6 999 100
6 999 105
6 999 110
6 999 115
6 999 120
Lifting chain
Draw bolt
Sleeve
Spanner
Draw bolt
Spanner
Spanner width across flats 2 5/8
Tooth segment
Gear
Tensioning tool
Centre support
Fitting tool
Bearing puller
Sleeve
Draw bolt
Press tool
Handle
Handle
Plug
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
Plate
16
VOLVO HT200
6 999 130
6 999 150
E
943
E
1215
E
1224
E
1228
E
1630
Puller
Plate
Plate
Guide pin, 2 pcs
Fixture
Fixture
Lifting eye
Gauge
Kukko 15-3
Kukko 17-2
Kukko 18-2
Kukko 18-3
Kukko 20-20
OTC 943 with bolt 515S
Bolt M8cut-off length 50 mm
Bolt M8, cut-off length 160mm
Bolt M10, length 60 mm, 2 pcs
Bolt M10, length 100mm, 3 pcs
Bolt M20, length 150mm, 4 pcs
Adjustable stand
Depth gauge, range 0-25 mm
Dial gauge with magnetic base
11 666 013
pump
11 666 014
Jack

,
Op.no. 43771
:
999 2628
999 3131
999 3387
999 3517
999 3538
999 3577
999 3582
999 3586
999 3590A
999 3598
999 3599
999 3616
999 3659
999 3712
999 3713
999 3716
6 999 001
6 999 002
6 999 010
6 999 060
6 999 070
2 5/8
17
VOLVO HT200
, 2
Kukko 15-3
Kukko 17-2
Kukko 18-2
Kukko 18-3
Kukko 20-20
OTC 943 with bolt 515S
M8, 50mm
M8, 160mm
M10, 60 mm, 2
M10, 100mm, 3
M20, 150mm, 4
, 0-25mm
11 666 013
11 666 014
Dismantling
1 Fit the transmission and check that the oil is drained. If the
filter is left on the transmission, remove the filter and its console.
On the HT201 also remove the oil draining pipe between gear
selector valve and dropbox housing.
HT201
2 Remove the damping valve

2
3 Remove the gear selector valve

3
6 999 080
6 999 088
6 999 090
6 999 100
6 999 105
6 999 110
6 999 115
6 999 120
6 999 130
6 999 150
E
943
E
1215
E
1224
E
1228
E
1630
18
VOLVO HT200
4 Mark and disconnect the oil hoses from the oil distributor
plate and remove outer and inner oil distributor plate and
intermediate plate.
NOTE: The socket head bolts which retain the inner plate and oil
pipes on the inside of the plate.
4
5
5
Mark and remove the hose from the lubricating oil valve and
remove the lubricating oil valve.
6 Remove the oil distributor plate and remove the oil pipes from
the oil distributor for second speed reverse.
NOTE: The pipes on the inside of the plate.
6
19
VOLVO HT200
7
7
8
8
9
9
Remove the cover from the torque converter, take care of any
shims. Undo any locking and remove the locking washer.
Lift up the torque converter.

Weight approx. 110Kg(243 Ib)
110Kg243Ib
Remove both the power take-offs.
20
VOLVO HT200
10 Remove the oil pipes for forward-first, reverse-second and

the connecting pipe to the torque converter foot. Also remove
the lubrication oil pipe for forward-first and reverse-second
and on HT201 the return oil pipe.
10
HT201
1
2
3
4
5
6
7
HT201
11
Remove the torque converter safety valve.

Take out spring and ball.
11
12 Remove any circlip from the turbine shaft.

Move pipe and spring guide for the torque converter safety valve
and remove the pump cover.
NOTE: Alternatively the oil pump can be removed as a complete
unit as shown in the figure.
Weight of complete oil pump approx.30 kg(66 Ib)
12
30KG66Ib
21
VOLVO HT200
13
13
Remove the oil distributors, torque converter foot and

turbine shaft.
14 Remove inner circlip, spacer ring (HT200) and support ring

from the reverse-second clutch shaft.
14 HT200
15 Remove outer circlip from the third-fourth clutch shaft.

15
22
VOLVO HT200
16
Remove the bolts for the housing halves and

lift up the front half.
Weight approx. 125Kg (276Ib)
Tap lightly on the third-fourth clutch shaft.
Make sure that all clutch shafts remain in the
Lower housing half.
16
125KG276Ib
-
17 Lift away intermediate gear.

17
18 Lift out the clutch shafts in the order:

reverse-second, forward-first and finally the
third-fourth shaft.
The weight of the clutch shafts are approx:
reverse-second 50 Kg(110Ib), forward-first 50
kg(110Ib)and third-fourth 30Kg(66Ib).
18
50kg110Ib 50Kg
110Ib 30Kg66Ib
23
VOLVO HT200
19
19
Remove the cover for the suction strainer and take out the
strainer.
20 Remove circlip, lock washer and the rear drive flange.

20
21
Remove the bearing retainer.

Take care of any shims.
21
24
VOLVO HT200
22 Remove circlip, lock washer and the front drive flange.
22
NOTEWith effect from transmission ser.no.2791 the lower

output shaft has been changed to the version shown blow.
2791
2791
TRANSMISSION ser.no.-2790
23 Remove the cover of the brake housing together with piston.
-2790
23
25
VOLVO HT200
24 Take out the brake discs.
Also remove the locking pin.
24
25
Take out the brake housing.

Use two bolts as puller screws.
NOTE: The threaded length of the bolts
should be increased to approx. 40 mm.
25
40mm
Continue according to point 27 page 36.
27.
26
VOLVO HT200
TRANSMISSION ser.no.2791-or rebuilt version
2791-
23
Remove the three plugs in the cover of the parking brake

and release the parking brake application by pulling in the
three bolts in the piston.
Remove the brake housing bolts and lift
away the cover together with piston and
spring
23
24
24
Pull away the bearing
25
25
Take out the brake discs.
27
VOLVO HT200
26
Take out the brake housing.

NOTE: Use screwdrivers or pincbars.
26
27
27
Lift out the output shaft.
28
28
Remove the splash plate.
29
Remove the cover and remove the bearing retainer for the
third-fourth shaft.
29 -
28
VOLVO HT200
30
Press the third-fourth shaft out of the gear.

NOTE: Hold the gear so that it does not fall
down to the bottom of the transmission.
30 -
31
31
Lift out the gear.
32
Remove the bearing cover for the

reverse-second clutch shaft and remove the
end washer of the shaft and the support ring
of the bearing.
32
29
VOLVO HT200
33
press out the gear wheel for the second speed and the clutch
drum.
NOTE: Hold the clutch drum so that it does not
fall to the bottom of the transmission housing.
33
34
34
Remove the tool and take out the gear wheel.
35
When required, drive all remaining bearing out

of the housing.
The bearing of the intermediate gear are pulled
out according to the figure.
35
30
VOLVO HT200
TORQUE CONVERTER, REBUILDING
When repairing torque converter up to and including 2464

transmission ser.no.2464, the torque converter should
be rebuilt as described below:
Regarding the changing of torque converter foot
when a circlip has been introduced w.e.fr.

1639 130
transmission ser.no.1639, see page 130.
1 In order to keep the stator according to earlier version, a recess
has to be milled out in the stator for the wear washer. Then drill
and ream a new hole for the guide pin.
1
1 Blunt end of rotor blade

2 Reference diameter
3 Reaming depth
2 Check that the thrust bearing has a running

clearance in the torque converter foot.
If this is not the case, the torque converter foot
Should be machined as described below.
2
31
VOLVO HT200
TORQUE CONVERTER, RECONDITIONING
Op. no. 43711

Tools:
999 2628
Lifting chain
6 999 001
Handle
6 999 065
Plate
6 999 115
Plate
Dial gauge with magnetic base
Dismantling
1 Mark the pump housing halves and part the halves.

1
2
2
Lift away turbine rotor and thrust bearing.
Remove the stator and thrust bearing.

For rebuilding of stator, see page 39.
3
32
VOLVO HT200
4
4
Lift up the thrust and oil distributor washers.
5
5
Remove the bolts and lift away the pump rotor.
6
6
Tap out the bearing.
33
VOLVO HT200
7
7
Remove the circlip.
8
8
Drive out the drive sleeve.
9
9
Drive the bearing out of the pump housing half.
10
10
Clean and change necessary parts.
34
VOLVO HT200
Assembling
11 Fit a new O-ring in the drive sleeve.

11 O
12 Drive in the bearing in the gear which drives the

power take-offs.
12
13 Fit the pump rotor on the gear which drives the power take-offs
according to earlier made marks.
Tighten the bolts to 95 N m(70 Ibf ft).
13
95N m70 Ibf ft.
35
VOLVO HT200
14 Fit the thrust and oil distributor washers in the pump housing
half.
NOTEThe locking of the washer in done with
the guide pin.
14
15 Fit the thrust bearing

15
16 Insert any existing shims and the thrust washer.

NOTE: The locking of the washer and the shims
with the guide pin.
NOTE: If parts which affect the end float have
been changed, the determination of the shim
thickness should be carried out according to point
23.Therefore, no shims should be fitted at this
stage.
16
23
36
VOLVO HT200
17 Position the stator
17
18 Insert the thrust washer and thrust bearing.

NOTE: The locking of the washer is done with
the guide pin.
18
19 Fit the turbine rotor.

19
37
VOLVO HT200
20 Position the cover

Use two bolts.
20
21 Drive the bearing into position in the pump

housing half.(Applies to HT200 up to and
including transmission ser.no.1638).
Drive the bearing against the cover.(Applies to
HT200 with effect from transmission
ser.no.1639 or rebuilt version and HT201)
21
1638
1639
HT200 HT201
22 Assemble the pump housing halves according to

earlier made marks.
Use only four bolts.
NOTE: The existing marks according to the
Figure on both the housing halves should be
Displaced 180erelative to each other.
22
180e
38
VOLVO HT200
23 Turn the torque converter. Make sure that
stator and turbine rotor are at the bottom.
Measure the total clearance between oil
distributor washer and thrust bearing.
Make sure that the feeler gauge on the E-tool
does not flex.
The reading on the dial gauge+ the thickness
of the feeler gauge=the total end float.
Select shims so that the clearance becomes
0.1-0.7 mm(0.004-0.028 in).
Make a note of the shim thickness.
23
E-
+=
0.1-0.7mm
0.004-0.028 in
24 Part the pump housing halves.

24
25 Lift away turbine rotor and thrust bearing

and remove the stator.
25
26 Heat the stator in an oven to approx.125

(257eF)and remove the thrust washer.
NOTE: If the stator is placed in the oven with
the washer turned downwards, the washer may, under
favourable conditions, fall out of
the stator.
26 125
257eF)
39
VOLVO HT200
27 With the stator still warm, position the shims
calculated in point 23 and the seat for the
thrust washer, provided washer and seat were
parted.
27 23
28 Position the thrust washer.

NOTE: The locking is done with the guide
pin.
Allow the stator to cool and make sure that
seat and thrust washer are at the bottom when
the parts have cooled down.
28
29 Position the stator.

29
30 Insert the thrust washer and thrust bearing.
NOTE: The locking is done with a guide pin.
31 Fit the turbine rotor.

31
32 Assemble the pump housing halves
according to earlier made marks.
Use only four bolts.
NOTE: The existing marks on both the
housing halves should be displaced 180erelative to each
other.
32
180e
40
VOLVO HT200
33 Position the torque converter with the cover
downwards. Make sure that stator and turbine
rotor are at the bottom. Check that the end float
between oil distributor washer and thrust
bearing is 0.1-0.7mm(0.004-0.028 in).
If the clearance is not within the prescribed
valve, the shims must be changed.
33
0.1-0.7mm(0.004-0.028in).
34 Drive the sleeve into position with a soft

Hammer and lock with the circlip.
34
35 Position all bolts in the pump housing halves.

Tighten the bolts to 55 N m(40 Ibf ft)
35
55N m40 Ibf ft
41
VOLVO HT200
OIL PUMP AND TURBINE SHAFT BEARING,
RECONDITIONING
Tools:
6 999 001
Handle
6 999 080
Plate
6 999 088
Plate
Puller OTC 943 with puller bolt 515S

OTC 943 515S
Flat bar 70*20 mm, thickness 5 mm
70*20 mm 5 mm
1 Mark and dismantle the oil pump.
Remove gear and shafts.
1
2 Clean and check all parts.

Change damaged and worn parts.
2
3 Position gear and shafts, thoroughly lubricated.

3
4 Assemble the oil pump.
4
5 When required, remove the circlip for the turbine shaft outer bearing
race from the pump housing and pull out the bearing race.
Remove the thrust washer.
Or alternatively, make a weld bead in three places evenly distributed in the
bearing race. Cool the bearing race and lift it out.
NOTE: Cover the recess in the housing for the thrust bearing with a wet rag
or similar.
5
42
VOLVO HT200
6 Remove the circlip and press off bearings and washers from the
tubing shaft.
Check that the lubricating hole in the shaft is open.
6
7 Change the turbine shaft sealing ring.

7
8 Heat inner thrust washer and bearings to approx.

100(212eF).
Fit thrust washer and bearings into positon.
The chamfer of the thrust washer should be turned
away from the shoulder.
100212eF)
9 Fit the spacer washer and lock with the circlip.

9
10 Fit the thrust bearing and position the sealing ring.

10
43
VOLVO HT200
11 Fit thrust washer, 5mm, into position, Turn the
chamfer downwards(against the torque converter)
and drive in the turbine shaft outer bearing race.
11 5mm
12 Fit the circlip.

12
44
VOLVO HT200
DAMPING VALVE, RECONDITIONING
Dismantling
1 Remove the two covers and take out the springs.

1
2 Take out pistons and springs.
2
3 Clean and change necessary parts.
Change the O-rings.
3
O
NOTE: There are two versions of the valve spool.
They are fully interchangeable. Use the same spool
version. The newer spool gives a smoother
gear-shift.
45
VOLVO HT200
Assembling
4 Fit pistons and springs into position.
4
5 Insert the springs and fit the covers.
5
GEAR SELECTOR VALVE, RECONDITIONING
Op.no.43709
Tools:
999 3577 Spanner(solenoid valve type ASCO)
999 3517 Spanner(solenoid valve type Skinner)
999 3577 ASCO
999 3517 Skinner
Dismantling
1 Remove cover and leads.

NOTE: The lead marking in the cover.
1
2 Loosen the solenoid valves and lift them up

NOTE: The star washers under the valves.
2
46
VOLVO HT200
3 Remove the retainer for the solenoid valves together with
valve spool and spring.
NOTE: The O-rings.
3
O
4 Remove the cover.

4
5 Remove the pressure-limiting valve spring together with the

guide.
5
6 Lift out springs and spools.

6
47
VOLVO HT200
7 When required the solenoid valve seats can be removed.

Use a small drift to drive out the seats.
7
8 Remove the cover.

8
9 Remove the pressure-limiting valve.

9
Change The O-rings.
10
O
48
VOLVO HT200
Assembling
11 Position the washer of the

pressure-limiting valve and the spring.
11
12 Drive the valve seats into position, if these were removed.

Lock with locking fluid, strong.
NOTE: The seat may be without a recess.
12
13 Bolt on the cover.

Tighten the bolts to 15 Nm(11 Ibf ft).
Bolt on the solenoid valve retainers
Together with valves, springs and O-rings.
NOTE: Make sure that the tapered end of
the spring sticks out of the valve.
Tighten to 12 Nm(9 Ibf ft)(Skinner)and 25
Nm(18 Ibf ft)(ASCO).
13
15 Nm11 Ibf ft
12 Nm9 Ibf ftskinner

25 Nm18 Ibf ftASCO
49
VOLVO HT200
14 Position the locking for the solenoid

Valves. A solenoid valve with separate
retainer for locking of all solenoids is
introduced on HT200 with effect from
transmission ser.no.2097 and on HT201.
Earlier version is provided with separate
toothed washers under each solenoid
valve.
14
HT200 2097
HT201.
15 Fit the solenoid valves.

NOTE: Earlier version socket head
Bolts.
Connect the leads.
For how to connect, see the
Marking inside the cover.
15
50
VOLVO HT200
16 Fit the cover.
16
17 Position spring and spool in the respective

Bores.
17
18 Position the spool for the clutch

pressure-limiting valve.
18
19 Check that all spools move easily and bolt on

the cover. Tighten the bolts to 15 Nm(11 Ibf
ft).
19
15Nm11 Ibf ft.
51
VOLVO HT200
LUBRICATING OIL VALVE, RECONDITIONING
Dismantling
1 Remove both end covers and take out spring,

washer and spool.
1
2
3 Insert spool, washer and spring.
NOTE: The stud of the spool towards
the washer.
Bolts on the end covers.
3
POWER TAKE-OFF, RECONDITIONING

Op.no.48201
Tools
6 999 001
6 999 050
6 999 065
Handle
Plate
Plate
Dismantling
1 Remove the circlip for the drive sleeve and take out the drive
sleeve.
1
2 Remove the outer circlip of the bearing.

2
3 Press out the shaft.
3
4 Press the bearing from the shaft.
4
5 Clean and check and change necessary parts.
5
52
VOLVO HT200
Assembling
6 Press the larger bearing onto the shaft.
NOTE: The bearing is positioned on the same side as the
circlip groove of the shaft.
6
7 Fit the smaller bearing in the housing.

7
8 Insert gear and spacer ring in the housing.
Press in the shaft together with the bearing.
Make sure that the pressing force is applied on
the inner race.
Lock with the circlip.
8
9 Fit the drive sleeve into position and lock with

the circlip.
9
53
VOLVO HT200
FORWARD AND FIRST CLUTCHES,
DISMANTLING AND ASSEMBLING
Dismantling
1 Place the shaft in the fixture and remove the

sealing rings(piston steel ring type)for the
forward clutch from the shaft.
Pull off the bearing.
Remove the thrust washer.
1
2 Remove the thrust bearing and the thrust

washer.
2
54
VOLVO HT200
3 Lift up the clutch drum.

3
4 Remove bearings, thrust washer, thrust

bearing and thrust washer.
4
5 Remove the circlip and lift away the thrust

plate.
5
55
VOLVO HT200
6 Lift up the disc pack
6
7 Apply the tool and remove the circlip.

NOTE: Make sure that the bolt of the tool
can be screwed in at least another 100mm(4
in), before starting to compress the spring.
NOTE: Compress the spring only so much as
to make it possible to remove the circlip.
7
100mm(4 in).
The force of the compressed spring is

1000-1100 N (225-247 Ibf)
1000-1100 N (225-247 Ibf)
8 Remove the tool, the clutch hub and the

spring.
8
56
VOLVO HT200
9 Lift up the support ring.

9
10 Remove the application piston.

Remove the sealing rings(piston steel ring
type) piston and the gear wheel.
10
11 Turn the shaft, pull off the bearing and

remove the spacer ring.
11
57
VOLVO HT200
12 Remove the circlip

12
13 Remove the wear ring by prising up the clutch

drum.
13
14 Lift up the clutch drum together with the bearing.

Remove the bearing and the wear ring.
The wear ring may be left in place and removed to
together with the hub according to point 19.
14
19
58
VOLVO HT200
15 Remove the coiled locking ring.
NOTE: When removing , make sure that the
end of the coiled locking ring is flush with
the end of the circlip, in order to be able to
remove the coiled locking ring.
15
16 Remove the locking ring for the disc pack

and lift up the thrust plate.
16
17 Lift up the disc pack

17
59
VOLVO HT200
18 Compress the return spring for the application piston.
NOTE: The thrust plate.
Remove the split locking washer.
NOTE: Make sure that the bolt on the tool has a
movement of at least 100mm(4 in), after starting to
compress the spring.
18
100mm
The force of the compressed spring is 1000-1100N(225247 Ibf)

1000-1100N225-247 Ibf
1
2
3
4
999 3598
999 3599-1
Thrust plate
Locking washer
19 Remove the tool and lift up the thrust washer, clutch

hub and spring and also the wear ring, if not removed
earlier.
19
20 Remove the application piston and remove the sealing

rings (piston steel ring type) from the shaft and the
piston.
20
60
VOLVO HT200
21 Check that the holes for the cooling oil in the
shaft and in the gear wheel align. It should be
possible to insert a drill bit with a thickness of
at least 5 mm through both holes. If this is not
possible, change the gear wheel.
The gear wheel is shrunk onto the shaft and
must thus be heated before it is pressed off
the shaft.
When necessary press the shaft out of the gear
wheel and the dual-stage application piston.
21
5mm
22 When necessary press the shaft out of

the gear wheel and the dual-stage application
piston.
Remove the circlip, clean and change
necessary parts. Make sure that the holes in
the gear wheel, pistons and the
ducts in the shaft are not clogged.
22
61
VOLVO HT200
Assembling
23 Heat the gear wheel and the dual-stage

application piston in an oven to approx.
100(212eF), if these parts where
Removed.
Check that the circlip for the dual-stage
application piston is in position on the shaft
and put on the piston and the gear-wheel.
NOTEMake sure that the dual-stage
application piston fits closely up against the
circlip even after the parts have cooled down.
23 100
212eF)
24 Turn the shaft and fit the sealing ring(piston

steel ring type)on the first clutch shaft end.
Lubricate the ring with petroleum jelly.
24
25 Position the sealing rings(piston steel ring type)

on the piston.
25
62
VOLVO HT200
26 Make the rings stay in position by coating them
with petroleum jelly and position the piston.
26
27 Position spring and hub.

Use a new spring.
The ID of the spring is approx.72mm(2.83 in)and
the number of coils is 4.5. The length of the hub
is approx.53mm(2.09 in).
27
ID 72mm(2.83in)
4.5 53mm(2.09in).
28 Position the tool and compress the spring using

the thrust plate as a support for the tool.
Make sure that the hub enters the splines.
Fit the locking ring halves with the chamfer
upwards.
28
29 Release the tension of the spring and make sure

that the locking ring halves engage correctly.
Remove the tool and the thrust plate.
29
63
VOLVO HT200
30 Position the discs.
Begin with an internally splined disc and then an
externally splined disc and so on.
There are 9 externally splined and 9 internally
splined discs.
The disc thickness is 2.0mm(0.08in).
The internal diameter of the discs is 99.1mm(3.90
in).
Lubricate the discs.
30
9 9
2.0mm(0.08 in)
99.1mm(3.90 in)
31 Position the thrust plate and secure with the

Circlip. Check the disc clearance which should be
1.7-5.0mm(0.067-0.197in).
31
1.7-5.0mm(0.067-0.197in)
32 Position the coiled locking ring.

32
64
VOLVO HT200
33 Position the wear ring approx.5.0mm(0.2 in),

and the bearing.
If necessary heat the ring to approx.100(212
eF).
Lubricate the bearing with oil.
33 5.0mm(0.2 in)
100212eF)
34 Position the clutch drum.

34
35 Position bearing and wear ring approx.5.0mm

0.2 in
If necessary heat ring to approx. 100
(212eF)
35 5.0mm(0.2in)
100(212eF)
65
VOLVO HT200
36 Position the circlip.

36
37 Check the end float which should be

0.2-1.0mm(0.008-0.040 in)
37 0.2-1.0mm0.008-0.040
in
38 Position the spacer ring, 5.0mm (0.2 in), heat

the bearing in an oven to approx. 100(212
eF) and position the bearing..
38 5.0mm(0.2 in),
100(212eF)
66
VOLVO HT200
39 Turn the shaft and position the sealing

rings(piston steel ring type) on the gear
wheel for the forward clutch.
Lubricate the rings with petroleum jelly.
39
40 Position the sealing ring(piston steel ring type) on the

piston.
40
41 Fix the ring with some petroleum jelly and

Position the piston.
41
67
VOLVO HT200
42 Position support ring, spring and hub.

Use a new spring.
The ID of the spring is approx.95 mm(3.74
In) and the number of coils is 4.5. The
length of the hub is approx.77 mm(3.03 in).
42
ID 95mm(3.74In),
4.5. 77mm(3.03 in).
43 Position the tool and compress the spring.

Make sure that the hub engages the splines.
NOTE: The hub only fits in one particular
position.
Make sure the circlip engages its groove
Correctly.
NOTE:Make sure the circlip engages its
groove correctly.
43
44 Remove the tool and position the discs.

Begin with an internally splined disc and
then one externally splined dis and so on.
There are 10 externally splined discs and 10
internally splined discs. The disc thickness
is 2.7mm(0.11 in).
The ID is 133mm(5.24 in)
44
10 10
2.7mm(0.11 in)
133mm(5.24 in)
68
VOLVO HT200

Circlip. Check that the disk clearance of the
Clutch is 1.9-5.3 mm(0.075-0.209 in).
45
1.9-5.3mm(0.075-0.209 in).
46 Position the thrust washer, thrust bearing and

another thrust washer.
NOTE: The thickness of the washers is 2.4
mm(0.09 in)and their ID is 54.2 mm(2.13
in).
Lubricate the parts.
46
2.4mm(0.09 in),
54.2mm(2.13 in).

47
48 Position the needle bearings.

48
69
VOLVO HT200
49 Position the thrust washers and the thrust

Bearing. Fit the thin thrust washer, 2.4 mm
(0.094 in) innermost and the thicker washer,
6.4 mm(0.25 in) outermost.
The ID of the washers is 54.2mm(0.13 in).
Lubricate the bearings.
49
2.4mm(0.094 in)
6.4mm(0.25 in)
54.2mm(0.13 in).
50 Heat the bearing in an oven to approx.100

212eFand position the bearing.
50 100212eF
51 Check the end float which should be 0.1-0.7

mm(0.004-0.028 in). If the clearance is too
great, change the thrust bearing and the thrust
washer.
NOTE: The sealing rings(piston steel ring
type) should be fitted to the shaft after the
end float has been adjusted.
51 0.1-0.7mm(0.004-0.028 in).
70
VOLVO HT200
REVERSE AND SECOND CLUTCHES,

DISMANTLING AND ASSEMBLING.
Dismantling
1 Press or alternatively pull off gear wheel and
bearing race.
1
2 Remove the thrust bearing and thrust

washers.
2
71
VOLVO HT200
3 Remove the clutch drum.

3
4 Remove the needle bearings.

4
5 Remove the thrust bearing and the thrust

washers.
5
72
VOLVO HT200
6 Remove the circlip for the disc pack and lift up the
thrust plate.
6
7 Lift up the disc pack.

7
8 Tighten down the tool and remove the circlip.

movement of at least 100 mm(4 in), after beginning
to compress the spring.
NOTE: Only compress the spring so much that the
circlip can be removed.
8
100 mm4 in
The force of the compressed spring is 1000-1100N

(225-247 Ibf).
1000-1100N (225-247 Ibf)
73
VOLVO HT200
9 Remove the tool and lift up the hub, spring and
support ring.
9
10 Remove the application piston and remove the

Sealing ringspiston steel ring typefrom the
Piston and the gear wheel.
10
11 Turn the shaft and remove the coiled locking ring

from the second clutch shaft end.
NOTE: When removing, make sure that the
coiled locking ring end is flush with the end of
the circlip in order to be able to remove it.
11
74
VOLVO HT200
12 Remove the circlip for the disc pack.
12
13 Lift up the thrust plate and lift up the disc pack.

13
14 Compress the return spring for the application

piston.
NOTE: Make sure that the bolt of the tool has a
movement of at least 100 mm(4 in), after starting
14
100 mm4 in
75
VOLVO HT200
15 Remove the tool and lift off the pressure plate,

Clutch hub and spring.
15

seals from the piston and the shaft.
16
17 Make sure that the holes for the cooling oil in

the shaft and in the gear wheel align. It should
be possible to insert a drill bit which is at least
5 mm thick through both boles. If this is not
possible the gear wheel must be changed.
The gear wheel is shrunk onto the shaft and
must therefore be heated before it is pressed
off.
17
5mm
76
VOLVO HT200
18 If necessary press the shaft out of the gear
wheel and the dual-stage piston.
18

Make sure that the holes in the gear wheel(one
from either side) in the pistons and the duct in
the shaft are not clogged.
19
Assembling
20 Heat the gear wheel and the dual-stage piston
in an oven to approx.100(212eF), if these
parts where removed. Check that the circlip for
the dual-stage piston is correctly positioned on
the shaft and fit piston and gear wheel.
NOTE: Make sure that the dual-stage piston fits
right up against the circlip, also when the parts
have cooled down.
20
100(212eF)
21 Turn the shaft and position the sealing ring(

piston steel ring type) on the second cluth shaft.
Lubricate the ring with petroleum jelly.
21
77
VOLVO HT200
on the piston.
22
23 Attach the rings by lubricating them with

petroleum jelly and fit the piston.
23
24 Position spring and hub.

Use a new spring.
The ID of the spring is approx.72 mm(2.83 in)
and the number of coils is 4.5. The length of the
hub is approx.53 mm(3.09 in).
24
72mm(2.83 in),
4.5 53mm(3.09 in)
78
VOLVO HT200
25 Position the tool and compress the spring. Use the
thrust plate as a support for the tool.
Fit the locking ring halves with the chamfer facing
upwards.
25

that the locking ring halves are correctly
positioned.
26
27 Fit the discs.

Begin with an internally splined disc and then one
Externally splined disc and so on. Turn the
rounded side of the teeth upwards.
There are 9 discs of each kind. The disc thickness
is 2.0 mm(0.08 in)
The ID of the discs is 99.1 mm(3.90 in).
27
9 2.0mm(0.08 in)
99.1 mm(3.90 in)
28 Postion the thrust plate and secure with the circlip.

Check the disc clearance of the clutch which
should be 1.7-5.0mm(0.07-0.20 in).
28
1.7-5.0mm(0.07-0.20 in)
79
VOLVO HT200
29 Position the coiled locking ring.

29
30 Turn the shaft and position the sealing rings

(piston steel ring type) on the gear wheel for the
reverse shaft.
30
31 Position the sealing ring(piston steel ring

type) on the piston.
31
80
VOLVO HT200
32 Fix the rings with some petroleum jelly and

position the piston.
32
33 Postion support ring, spring and hub.

Use a new spring.
The ID of the spring is approx.95 mm(3.74 in),
and the number of coils is 4.5. The length of
the hub is approx.77 mm(3.03 in).
33
95mm(3.74 in),
4.5 77mm(3.03 in)
34 Position the tool and compress the spring.

Make sure that the hub engages the spines.
NOTE: The hub only fits in one position.
Fit the circlip.
NOTE: Make sure the circlip engages its
groove correctly.
34
81
VOLVO HT200
35 Remove the tool and position the discs.

Begin with an internally splined disc and
then fit an externally splined disc and so on.
The number of disc are 10 of each kink. The
disc thickness is 2.9mm(0.11 in)
The ID of the discs is 133 mm(5.24 in).
35
10 2.9mm
(0.11 in)
133mm(5.24 in)

Circlip.
Check the disc clearance which should be
1.9-5.3 mm(0.07-0.21 in).
36
1.9-5.3mm(0.07-0.21 in)
37 Position thrust washer, thrust bearing and

another thrust washer.
NOTE: The thickness of the thrust washers is
2.4 mm(0.09 in).The ID of the discs is 54.3
mm(2.14 in).
Lubricate.
37
2.4mm(0.09 in).
54.3 mm2.14 in
82
VOLVO HT200
38 Postion the clutch drum.

38
39 Postion the needle bearings.

Lubricate.
39
40 Position the thrust washers and the thrust bearing.

The thickness of the washers is 2.4mm(0.09 in)
and the ID is 54.3 mm.
Lubricate.
40
2.4mm(0.09 in), 54.3mm
83
VOLVO HT200
41 Heat the gear wheel and the inner bearing race to

approx. 100 and 212eF and fit the gear and the
bearing race into position.
41 100 210eF
42 Check that the gear wheel and the bearing race fit
up against the shoulder when they have cooled
down.
Check the end float which should be 0.2-1.5 mm
(0.008-0.059 in).
If the clearance is too great, change thrust bearing
and thrust washers.
NOTE: The sealing rings(piston steel ring type)
should be fitted on the shaft after adjusting the
shaft end float in the transmission.
42
0.2-1.5mm(0.008-0.059in).
84
VOLVO HT200
THIRD AND FOURTH CLUTCHES,
DISMANTLING AND ASSEMBLING
Dismantling
1 Remove the sealing ring(piston steel ring type)

from the shaft.
NOTE: With effect from transmission ser.no.2206
the clutch drums and the externally splined discs
are the same as those in the other clutches. Other
parts have not been changed and therefore, earlier
type clutch shafts can be rebuild to the new type.
See also figure on page 148.
1
2206
148
2 Remove the circlip and the spacer ring and pull off
the bearing.
2
3 Remove the spacer ring and lift up thrust bearing

and thrust washer.
3
85
VOLVO HT200

4
5 Remove the needle bearing.

5
6 Remove washers and thrust bearings.

6
86
VOLVO HT200

NOTE: In order to be able to remove the coiled
locking ring from its groove, its end should be flush
with the end of the circlip.
7
thrust plate.
8
9 Lift up the disc pack.

9
87
VOLVO HT200

piston.
10
100mm(4 in)

(225-247 Ibf).
1000-1100N(225-247 Ibf)
11 Remove the tool and lift up the thrust plate, clutch

hub and spring.
11

sealing rings(piston type rings) from the shaft
and the piston.
12
88
VOLVO HT200
13 Turn the shaft and remove the circlip.

13
14 Remove washers and thrust bearing.

14

15
89
VOLVO HT200
16 Remove both needle bearings.
16
17 Remove washers and thrust bearing.

17

NOTEIn order to be able to remove the coiled
locking ring from its groove, its end should be
flush with the end of the circlip.
18
90
VOLVO HT200
thrust plate.
19
20 Remove the disc pack.

20

piston.
NOTEThe thrust plate.
NOTE: Make sure that the bolt of the tool has a
21
100mm(4 in)

(225-247 Ibf).
1000-1100N(225-247 Ibf)
91
VOLVO HT200
22 Remove the tool and lift up the thrust plate,

clutch hub and spring.
22

sealing rings(piston steel ring type) from the shaft
and the piston.
23

Make sure that the holes in the separator plate and
the ducts in the shaft are not blocked.
24
92
VOLVO HT200
Assembling
25 Postion the sealing ring(piston steel ring type)

on the third clutch shaft.
25
26 Postion the sealing rings(piston steel ring type)

on the piston.
26
27 Fix the rings with some petroleum jelly and

position the piston.
27
93
VOLVO HT200
28 Postion the spring and the hub.

Use a new spring.
The ID of the spring is approx.72mm(2.83 in) and
the number of coils is 4.5. The length of the hub is
approx.52 mm(2.05 in).
28
72mm(2.83 in) 4.5

52mm2.05 in
29 Position the tool and compress the spring. Use the

thrust as a support for the tool.
upwards.
29
30 Release the spring tension and make sure that the

locking ring halves engage their grooves correctly.
30

Begin with an internally splined disc then one
externally splined disc and so on.
There are twelve externally splined discs and
thirteen internally splined discs. The disc thickness
is 1.5mm(0.06 in).
The ID of the disc is 99 mm(3.90 in).
31
12 13
1.5mm0.06 in
99 mm3.90 in
94
VOLVO HT200
32 Postion the thrust plate and secure with the
circlip.
Check the disc clearance of the clutch which
should be 1.3-4.9mm(0.06-0.19 in).
32
1.3-4.9mm0.06-0.19
in
33 Fit the coiled locking ring in position.

33
34 Position thrust washer and thrust bearing.

Place the thinner thrust washer 1.5mm(0.06
in) innermost and the thicker washer 2.4 mm
(0.09 in)outermost.
Lubricate the bearings.
34
1.5mm
2.4mm
95
VOLVO HT200
35 Position the needle bearings.

35

36
37 Fit washer and thrust bearing.

NOTE: The thickness of the washer is 2.4mm(0.09
in).Fit the spacer ring, thickness 5 mm(0.20 in).
37
2.4mm0.09 in
5mm0.20in
96
VOLVO HT200
38 Fit the circlip.
38
39 Press the spacer ring up against the circlip and check

the end float which should be 0.4-1.3mm(0.0160.051 in).
If the clearance is too great, change the thrust bearing
and the thrust washer.
39
0.4-1.3mm0.016-0.151 in
40
97
VOLVO HT200

on the piston.
41
42 Fix the rings with petroleum jelly and position

the piston.
42
43 Position the spring and the hub.

Use a new spring.
The ID of the spring is approx.72 mm(2.83 in)
and the number of coils is 3.5. The length of the
hub is approx.38 mm(1.50 in).
43
72mm2.83 in
3.5 38mm1.50 in
98
VOLVO HT200
44 Position the tool and compress the spring. Use

the thrust plate as a support for the tool.
Upwards.
44

that the locking ring halves engage their
grooves.
45

Begin with an internally splined disc and then
continue with an externally splined disc and so
on.
The number of discs are 7 externally splined and
8 internally splined discs. The disc thickness is
1.5 mm(0.06 in).
The ID of the discs is 99mm(3.90 in).
46
7 8
1.5mm0.06 in
99mm3.90 in

Circlip. Check that the clutch disc clearance is
1.2-4.0 mm(0.05 in-0.16 in).
47
1.2-4.0mm0.05 in
-0.16 in
99
VOLVO HT200
48 Fit the coiled locking ring.

48
49 Position thrust washers and thrust bearing.

The thin thrust washer 1.5 mm(0.06 in) should be
fitted innermost and the thicker washer 2.4 mm(0.09
in)should be fitted outermost.
The ID of the washers is 54mm(2.13 in).
Lubricate the bearing.
49
1.5mm0.06 in
2.4mm0.09 in
54mm2.13 in
50 Position the needle bearing.

50
100
VOLVO HT200

51
52 Fit the thrust washer and thrust bearing.

The thickness of the washer is 2.4mm(0.09 in)and
its ID is 54mm(2.13 in).
Fit the spacer washer on top of the thrust bearing.
The thickness of the spacer washer is 5 mm(0.197
in) and its ID is 46 mm(1.81 in).
52
2.4mm0.09 in 54mm
2.13 in
5mm0.197 in
46mm
1.81 in
53 Heat the bearing in an oven to approx.100(212

eF)and fit the bearing.
The groove in the bearing should be facing
upwards.
53 100(212eF)
101
VOLVO HT200
54 Fit the spacer washer and secure with the circlip.

54
55 Press the bearing upwards and check the end float

which should be 0.5-1.5 mm(0.02 in-0.06 in).
If the clearance is too great, change thrust bearing
and washers.
NOTEThe sealing rings(piston steel ring type)
should be fitted on the shaft after adjusting the end
float.
55
0.5-1.5mm(0.02in-0.06in)
102
VOLVO HT200
TRANSMISSION, ASSEMBLING
Reverse-second output shaft

-
36 Remove the circlip for the inner bearing for

the second clutch drum and change the
bearing.
Refit the circlip.
36
37 Pull off the bearing inner race for the second

Clutch drum, if the bearing is to be changed.
37
38 Heat the inner bearing race to approx.100

212eFand fit the inner race.
38 100(212eF
103
VOLVO HT200
39 Fit the bearing and the gear for the reverse-second
clutch output shaft.
NOTE: The protruding hub boss should be facing
downwards( towards the dropbox).
If necessary heat the bearing in an oven to
approx.100(212eF).
39 -
100(212eF)
40 Insert the output gear for the second clutch and

the clutch drum in the outer gear.
40
41 Press the output gear into position

NOTE: Make sure that the bearing enters
squarely.
41
104
VOLVO HT200
42 Heat the inner bearing race for the second
clutch shaft to approx. 100(212eF) and fit
it on the shaft.
NOTE: The support hitch of the bearing race
should be innermost.
42
100212eF
43 Fit the bearing and the support ring.

43
44 Screw down the hexagon head bolts flush with

the contact face on the washer to the shaft and
tighten the bolts to 40 Nm(30 Ibf ft)
Lock with the hexagon socket bolts tightening
them to 20 Nm(15 Ibf ft).
Tighten finally to 80 Nm(59 Ibf ft).
Change the O-ring on the bearing cover and
bolt on the cover.
44
40 Nm30 Ibf ft
20 Nm(15 Ibf
ft)
80 Nm(59 Ibf ft)
O
105
VOLVO HT200
Third-fourth output shaft
45 Remove the bearing from the third-fourth
output shaft.
45 -
46 Drive the outer bearing race into position on the

third-fourth output shaft.
Position the bearing.
approx.100(212eF).
46 -
100(212eF)
47 Insert the gear(protruding hub boss away from

the torque converter side).
approx.100(212eF).
47
100(212eF)
106
VOLVO HT200
48 Position shaft and tool.

48
49 Make sure that the tool centres on the inner

bearing race. Press the shaft into the gear
wheel and the bearing.
49
50 Heat the bearing in an oven to approx.100

(212eF)and fit it. Make sure that the bearing
fits up against the shoulder when it has cooled
down.
50 100(212eF)
107
VOLVO HT200
51 Change the bearing race in the bearing
retainer for the third clutch outer shaft.
51
52 Bolt on the bearing retainer without an O-ring

with three bolts and washers as shown in the
figure. Tighten the bolts until the wavy
washers become fully compressed. Then
slacken the bolts approx. one turn in order to
release any preload.
NOTE: While tightening the bolts, make sure
that the bearing retainer slides easily in the
housing and that the retainer is not in an
oblique position when the bolts have been
slackened.
Rotate the shaft at least five revolutions.
Measure the slot where the shims are to be
fitted in at least two places. Work out the
average thickness.
Select and reduce the shim thickness so that
a preload of 0.03-0.08 mm(0.0012-0.0031 in)
is obtained.
52
0.03-.008mm(0.0012-0.0031 in)
O
108
VOLVO HT200
53 Bolt on the cover.
Use a new O-ring and tighten the bolts to 45 Nm
33 Ibf ft.
53
O 45 Nm33 Ibf ft
Output shaft
54 Change bearings and O-rings on the output shaft.
Pull off the bearings as shown in the figure.
54 O
Heat the bearings in an oven to approx.100(212eF)

and fit them.
NOTE: If necessary the shaft is pressed out of the gear
wheel.
Heat or press the shaft back into position.
100(212eF)
109
VOLVO HT200
55 Bolt on the splash plate.
Insert the shaft.
NOTEOn HT200 ser.no.2791-and on HT201,
there is no bearing fitted.
55
45 Nm33 Ibf ft
HT200 2791 HT201
56 Change the O-ring and on HT200 ser.no.-2790 also

the outer bearing race in the parking brake
housing.
Lubricate the O-ring with petroleum jelly.
Position the brake housing.
56 O HT200 2790
57 Position the guide pin for the brake discs and insert
the discs.
Begin with one internally splined and then
continue with one externally splined disc and so
on.
There are 7 internally, and 6 externally splined
discs.
57
7 6
110
VOLVO HT200
58 On transmission HT200 ser.no.2791-and on

HT201.
Heat the bearing in an oven to approx.100
(212eF)and position the bearing.
Make sure the bearing fits up against the
shoulder when it has cooled down.
58 HT200 2791 HT201
100(212eF)
Piston unit for parking brake, HT200 ser.no.-2790,

reconditioning
HT200 2790
59 Remove the piston unit from the parking

brake housing cover.
Slacken the bolts evenly all the way round.
NOTE: The force of the spring.
59
60 Change the O-ring and if necessary the

springs.
The free length of the springs should be 74.3
mm(2.93 in)and 66 mm(2.60 in)at a pressing
force of 900-1100N(202-247 Ibf).
Change the seal.
Drive the seal into position using handle and
Plates.
60 O
74.3mm(2.93 in), 9001100N202-247 Ibf 66mm
2.60 in
111
VOLVO HT200
61 Dismantle piston and piston stop.
Change the piston and the sealing rings and
the under-lying O-rings.
To facilitate the fitting of the sealing rings,
they may be heated in warm water which will
make them more supple.
Fit the sealing rings without using hard or
sharp objects.
NOTE: The lips of the sealings should be
facing each other.
61
O
O
62 Lubricate the rings with oil and assemble

piston and piston stop.
62
112
VOLVO HT200
63 Fit the piston unit on the cover for the parking brake
housing.
It may be necessary to rotate the piston stops
slightly to make the bolts fit.
Tighten the bolts to 25 Nm18 Ibf ft.
63
25 Nm18 Ibf ft
64 Release the parking brake application by tightening

in the three bolts in the cover until stop. Then
slacken the bolts one turn.
64
65 Fit the brake housing cover.

NOTE: The O-ring.
65
O
45 Nm(33 Ibf ft).
113
VOLVO HT200
Piston unit for parking brake,
HT200 ser.no.2791-and HT201reconditioning
HT200 2791 HT201

58 Remove the three bolts from the cover.
Slacken the bolts evenly all the way round.
NOTE: The spring force.
Lift away the cover.
58
59 Change seal and bearing race in the cover.

59
114
VOLVO HT200
60 If necessary remove the springs.

The free length of the springs should be 74.3
mm(2.93 in)and 66mm(2.60 in)at a pressing
force of 900-1100N(202-247 Ibf).
Change the sealing rings.
To facilitate the fitting, heat the rings in hot
water making them more supple.
Fit the sealing rings without using hard or
sharp objects.
NOTE: The lips of the seals should be facing
each other.
60
74.3mm2.93 in
900-1100N202-247 Ibf
66mm
61 Position the O-ring on the shaft outside the

bearing and also the O-ring on the housing.
Lubricate the sealing rings on the piston and
the chamfered surfaces in the housing with
petroleum jelly.
Position the piston.
Make sure that the sealing ring enters into to
chamfered area.
61 O
115
VOLVO HT200
62 Position the springs on the piston and put on
the cover. Make sure that the springs remain
located in their positions. Tighten down the
cover as far as the bolts allow. Tighten the
bolts evenly all the way round. Check that the
sealing ring on the piston enters the housing
evenly all the way round.
62
63 Fit the ordinary attaching bolts for the cover

tightening them evenly all the way round to
a torque of 45 Nm(33 Ibf ft).
Replace the three long bolts.
63
45 Nm(33 Ibf ft)
64 Release the parking brake application by

tightening in the three bolts in the cover
until stop. Then slacken them one revolution.
64
65 Fit the space between the lips of the seals with

grease.
65
116
VOLVO HT200
Transmission, assembling
66 Change seal and bearing race in the bearing

retainer for the output shaft.
Use handle 6 999 001, plate 6 999 080 and
6 999 105 for the seal and handle 6 999 001,
Plate 6 999 105 and 6 999 120 for the bearing
race.
66
6 999 001 6 999 080 6 999
105 6 999 001
6 999 105 6 999 120
67 Bolt on the bearing retainer without an O-ring
with three bolts and washers as shown in the
figure. Tighten the bolts until the wavy
washers become fully compressed. Then
slacken the bolts approx. one turn in order to
release any preload.
NOTE: While tightening the bolts, make sure
that the bearing retainer sliders easily in the
housing and that the retainer in not in an
slackened.
Rotate the shaft at least five revolutions.
Measure the clearance where the shims are to
be fitted in at least two places. Work out the
average.
Select shims whit a correct thickness reduced
by 0.03-0.08mm(0.0012-0.0031 in) in order to
obtain a preload.
Fit a new O-ring.
NOTE: It is important that the parking brake is
released as described on page 121 point 64 or
alternatively page 124 point 64.
67
0.03-0.08mm(0.0012-0.0031 in)
O 64
117
VOLVO HT200
68 Position the bearing retainer together with shims
and O-ring.
Tighten the bolts to 45 Nm(33 Ibf ft)
Fit a new O-ring on the shaft.
68 O
45 Nm33 Ibf ft
O
69 Fit the rear drive flange.

Tighten the nut to 600 Nm443 Ibf ft
NOTEThe tool increases the torque on the nut
15 times.
Secure with the circlips.
69
600 Nm443 Ibf ft
15
70 Fit the front drive flange.

Tighten the nut to 600 Nm(442 Ibf ft).
NOTE: The tool increases the torque on the nut 15
times.
Secure with locking washer and circlip.
There are two versions of the washer. The
difference between them is the pitch. Before
removing the tool, try out which locking washer
fits best. Never reduce the torque of the nut.
Remove the tool.
70
600 Nm(442 Ibf ft)
15
118
VOLVO HT200
71 Drive the plug out of the cover for the
forward-first clutch shaft. Put the cover back but
without an O-ring and without shims leaving a
slot between the cover and the housing of a
approx.1 mm(0.04 in).
71 -
O
1mm(0.04 in)
72 Drive the bearing for the forward-first clutch

shaft into position.
72 -
73 Position the clutch shafts in the housing in the

following order:
third-fourth, forward-first and finally
reverse-second.
NOTE: Grease the rollers in the output shaft for
the reverse-second clutch. Make sure that none of
the rollers fall out of the cage. When in doubt,
remove the cover at the end of the dropbox for
the reverse-second output shaft in order to check
that all rollers are in position. The reverse-second
clutch shaft must be shaken down in order to
make the disc splines engage.
The shaft is fully home when the reverse gear is
at the same level as the gear for the fourth clutch.
73
---
-
-
-
119
VOLVO HT200
74 Position the bearing for the intermediate gear.

74
75 Position the intermediate gear.

75
76 Turn the torque converter housing and drive in

the outer bearing race for the bearing of the
forward-first clutch shaft.
76 -
120
VOLVO HT200
77 Place guards over the clutch shafts, i.e. plastic,
rubber or similar and assemble the housing halves.
Do not forget the O-ring on the suction duct.
Use sealing compound.
NOTEThe torque converter housing must be in
the horizontal position when assembling,
otherwise the bearings may be damaged.
77
80 Nm59 Ibf ft.
78 Lubricate the bearing for the reverse-second clutch

shaft and drive the bearing into position.
Secure with the circlip.
78 -
79 Fit support ring, spacer ringHT 200and circlip

on the clutch shaft.
NOTEThe inner chamfer of the support ring
should be facing the torque converter(outwards).
Press down the circlip by raising the shaft while at
the same time pressing down the circlip using the
tool 999 3616.
79 HT 200
999 3616
121
VOLVO HT200
80 Put the outer circlip for the third-fourth clutch shaft on the shaft.
Lift the shaft with the aid of the tool and insert the circlip.
80 -
81 Fit the turbine shaft.

81
NOTEOn HT200 ser. no. 1639-a circlip has been introduced on the turbine shaft to
limit its end movement, see figure.
If parts of the torque converter are damaged, a change to the new version should be
made as follows:
If earlier type shaft or cover are damaged, the shaft, cover and torque converter foot
must be changed. Any shims are omitted and instead replaced by the circlip.
If the torque converter is damaged, change shaft and torque converter foot in addition
to the torque converter. The circlip is added.
If the torque converter foot is damaged, no other parts need to be changed apart from
the torque converter foot. The earlier version of the torque converter foot can be used
if 5 mm(0.20 in) is milled off at the splines end, see figure.
For further information of rebuilding the torque converter, see page 39.
HT200 1639
5mm(0.20 in)
39
122
VOLVO HT200
82 Position the gasket and fit the torque converter

simultaneously with the spring guide for the torque
converter safety valve.
Thoroughly lubricate and fit the lubricating oil pump
gears in the pump housing.
Fit the intermediate plate.
Fit the pump unit to the torque converter foot.
Tighten the oil pump attaching bolts to 45 Nm(33 Ibf
ft).
82
45 Nm(33 Ibf ft)
83 Fit the circlip

NOTE: This only applies to HT200 ser.no. 1639-or
the rebuilt version of HT201.
83
HT200 1639 HT201
84 Fit the sealing rings(piston steel ring type) on the

clutch shafts using petroleum jelly. Position the oil
distributors.
Tighten the oil distributor bolts to 25 Nm(18 Ibf ft).
84
25 Nm(18 Ibf ft)
123
VOLVO HT200
85 Fit the lubricating oil pipe.

85
86 Fit the oil pipes for the forward-first and

reverse-second oil distributors and the oil pipe to
the transmission oil pump.
Bolt on the retainer for the pipes.
Use new O-rings and lubricate with petroleum
jelly.
86 --
87 Fit the oil pipes and bolt on the oil distributor

plate and the lubricating oil valve.
87
25 Nm(18 Ibf ft).
124
VOLVO HT200
88 Fit the torque converter safety valve(ball and
spring).
88
89 Fill the pump with approx.1/4 of a litre (1/2 US

pint) of oil in the pump.
89 1/4 1/2
90 Fit the torque converter.

NOTE: The torque converter should be edge to
edge or just below the end of the turbine shaft.
90
91 Fit the turbine shaft locking washer(if required).

Lock the bolts.
Use locking fluid medium if locking washer are
missing.
91
40 Nm(31 Ibf ft)
125
VOLVO HT200
92 HT200 ser.no.-1638 not the rebuilt version:
Make sure that the circlip for the bearing on
the turbine rotor fits up against the torque
converter and measure the distance between
the turbine rotor outer bearing race and the
contact surface for the cover.
Make a note of the measurement.
Measure the corresponding distance within the
Cover.
Adjust with the aid of shims so that the
bearing gets a clearance of 0.15-0.35mm(
0.006 in-0.014 in).
92 HT200 1638
0.15-0.35mm(0.006 in-0.014 in).
93 Tighten the cover bolts to 40Nm(30 Ibf ft).

93 40Nm(30 Ibf ft)
94 Fit the gasket and the inner oil distributer

plate.
Use guide pins.
Centre the plate and tighten down the four
socket head bolts.
Tighten to 25 Nm(18 Ibf ft).
NOTE: Make sure that the pipes engage the
holes in the plate.
94
25 Nm(18 Ibf ft).
126
VOLVO HT200
95 Fit gasket, intermediate plate, gasket and

outer oil distributor plate.
Centre the plate and tighten the bolts to 25
Nm(18 Ibf ft).
NOTEEight M8 bolts length 55 mm and
two M8 length 25 mm.
95
25 Nm18 Ibf ft
55 M8 25
M8
96 Fit gasket and position the gear selector

valve.
Use guide pin.
Fit two M8 bolts length 120 mm(=the
ordinary attaching bolts)loosely.
96
120mm M8
97 Fit a gasket and the damping valve.

Tighten the valve bolts to 25 Nm(18 Ibf ft)
NOTE: Six M8 bolts length 160 mm.
97
25 Nm(18 Ibf ft)
6 160mm M8
127
VOLVO HT200
98 Connect all oil hoses.
Fit the oil draining pipe between the gear
selector valve and the dropbox(HT201).
98
HT201
99 Fit the oil strainer and bolt on the cover.

Tighten the strainer attaching bolts to 25Nm(18
Ibf ft)and the cover to 20Nm(15 Ibf ft).
The screw stud for the strainer should be secured
with locking fluid which can stand a temperature
of 150(300eF).
99
25Nm(18 Ibf ft)
20Nm(15 Ibf ft)
150(300eF)
100 Check and adjust the end float for the
forward-first clutch shaft by bolting down the
bearing retainer without an O-ring with three
bolts and washers as shown in the figure.
Tighten the bolts until the wavy washers
become fully compressed. Then slacken the
bolts approx. one turn in order to release any
preload.
NOTEWhile tightening the bolts, make sure
that the bearing retainer slides easily in the
housing and that the retainer is not in an
slackened.
Rotate the shaft at least 5 revolutions.
Measure the clearance where the shims are to
be fitted in at least two places. Calculate the
average value.
The correct end float should be 0.15-0.22mm
(0.006-0.009 in).
100
-
128
VOLVO HT200
0.15-0.22mm(0.006-0.009 in)
101 Fit the plug in the cover.
101
102 Bolt on the power take-offs.

102
45 Nm(33 Ibf ft)
103 Remove the bolts which were used for releasing

the parking brake and instead fit plugs.
103
129
VOLVO HT200
Drawings of E-tools which can be made in your own

Workshop
E-
E 943 Guide pin

Blank, bolt part no.955332
E 943
955332
E 1215 Fixture
E 1215
130
VOLVO HT200
E 1224 Fixture
Material: SIS 1312
A Spacer, 4 pcs
E 1224
SIS 1312
A 4
E 1228 Lifting eye

A Blank 445 mm. Material SIS 2172
B Bolt M8 length 50 mm part no.955 300
E 1228
A 445mm SIS 2172
B M8 50mm 955 300
E 1630 Gauge
1 Self tapping screw, e.g. part no. 955 137
2 Feeler gauge
3 pipe
E 1630
1 955 137
2
3
131
VOLVO HT200
132
VOLVO HT200
Clutch shaft, forward-first, HT200 -HT200
1 Gear wheel, forward
2 Gear wheel, first
3 Shaft
4 Draining holeclutch pressure
5 Gear wheel
6 Application piston
7 Split locking washer
8 Oil duct, forward clutch
9 Oil duct, first clutch
10 Lubricating oil duct, bearings
11 Lubricating oil duct, discs
12 Sealing rings(piston steel ring type)
13 Sintered discs
14 Steel discs
15 Draining hole, lubricating oil
16 Disc pack return spring
17 Taper roller bearing
18 Spacer washer
19 Thrust plate
20 Circlip
133
VOLVO HT200
134
VOLVO HT200
Clutch shaft, reverse-second, HT200 -HT200
1 Gear wheel, reverse
2 Gear wheel, intermediate gear
3 Shaft
4 Draining hole, clutch pressure
5 Gear wheel
8 Oil ductreverse clutch
9 Oil duct, second clutch
13 Sintered discs
14 Steel discs
19 Thrust plate
20 Circlip
21 Bearings
135
VOLVO HT200
136
VOLVO HT200
Clutch shaft, third-fourth, HT200 ser.no.-2205 -HT200 2205
1 Gear wheel, third
2 Gear wheel,fourth
3 shaft
5 Separator plate
8 Oil duct, third clutch
9 Oil duct, fourth clutch
11 Lubracating oil duct, discs
13 Steel discs
14 Sintered discs
18 Spacer washer
19 Thrust plate
20 Circlip
21 Bearings
137
VOLVO HT200
138
VOLVO HT200
Cluthc shaft, third-fourth, HT200 ser.no.2206- -HT200 2206
1 Gear wheel, third
2 Gear wheel, fourth
3 Shaft
5 Separator plate
12 Sealing rings
13 Steel discs
14 Sintered disc
18 Spacer washer
19 Thrust plate
20 Circlip
21 Bearings
139
VOLVO HT200
140
VOLVO HT200
Clutch shaft, forward-first HT201 -HT201
1 Gear wheel, forward
2 Gear wheel, first
3 Shaft
5 Gear wheel
8 Oil duct, forward clutch
9 Oil duct, first clutch
13 Sintered disc
14 Steel discs
17 Taper roller bearings
18 Spacer sleeve
19 Thrust plate
20 Circlip
141
VOLVO HT200
142
VOLVO HT200
Clutch shaft reverse-second HT201 - HT201
1 Gear wheel, reverse
2 Gear wheel, intermediate gear
3 Shaft
5 Grear wheel
8 Oil duct reverse clutch
9 Oil duct,second clutch
13 Sintered discs
14 Steel discs
19 Thrust plate
20 Circlip
21 Bearings
143
VOLVO HT200
144
VOLVO HT200
Clutch shaft third-fourth HT201 -HT201
1 Gear wheel, third
2 Gear wheel, fourth
3 Shaft
5 Separator plate
10 Lubricating oil duct,bearings
11 Lubricating oil duct,discs
13 Steel discs
14 Sintered discs
18 Spacer washer
19 Thrust plate
20 Circlip
21 Bearings
145
VOLVO HT200
146
VOLVO HT200
1 1639
2 2465
3 2465
4 1639
147

Workshop Manual Transmission of HT200 SDLG Volvo

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Workshop Manual Transmission of HT200 SDLG Volvo

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VOLVO HT200

Symbol diagram, neutral position HT200, ser. no.-2003 HT200-2003

Symbol diagram, neutral position HT201

Flow diagram, neutral position. HT200 ser.no.-2003

Forward damping valve

2 Remove the damping valve

3 Remove the gear selector valve

Lift up the torque converter.

Remove both the power take-offs.

10 Remove the oil pipes for forward-first, reverse-second and

Remove the torque converter safety valve.

12 Remove any circlip from the turbine shaft.

Remove the oil distributors, torque converter foot and

14 Remove inner circlip, spacer ring (HT200) and support ring

15 Remove outer circlip from the third-fourth clutch shaft.

Remove the bolts for the housing halves and

17 Lift away intermediate gear.

18 Lift out the clutch shafts in the order:

20 Remove circlip, lock washer and the rear drive flange.

Remove the bearing retainer.

NOTEWith effect from transmission ser.no.2791 the lower

Take out the brake housing.

Remove the three plugs in the cover of the parking brake

Pull away the bearing

Take out the brake discs.

Take out the brake housing.

Lift out the output shaft.

Remove the splash plate.

Press the third-fourth shaft out of the gear.

Lift out the gear.

Remove the bearing cover for the

Remove the tool and take out the gear wheel.

When required, drive all remaining bearing out

When repairing torque converter up to and including 2464

Regarding the changing of torque converter foot

when a circlip has been introduced w.e.fr.

1 Blunt end of rotor blade

2 Check that the thrust bearing has a running

Op. no. 43711

Dial gauge with magnetic base

1 Mark the pump housing halves and part the halves.

Lift away turbine rotor and thrust bearing.

Remove the stator and thrust bearing.

Lift up the thrust and oil distributor washers.

Remove the bolts and lift away the pump rotor.

Tap out the bearing.

Remove the circlip.

Drive out the drive sleeve.

Drive the bearing out of the pump housing half.

Clean and change necessary parts.

11 Fit a new O-ring in the drive sleeve.

12 Drive in the bearing in the gear which drives the

95N m70 Ibf ft.

15 Fit the thrust bearing

16 Insert any existing shims and the thrust washer.

18 Insert the thrust washer and thrust bearing.

19 Fit the turbine rotor.

20 Position the cover

21 Drive the bearing into position in the pump

22 Assemble the pump housing halves according to

24 Part the pump housing halves.

25 Lift away turbine rotor and thrust bearing

26 Heat the stator in an oven to approx.125

28 Position the thrust washer.