Volvo I-Shift Dis/assembly procedure step by step

Volvo I-Shift / Renault Optidriver

Dis/assembly procedure

A thorough explanation step by step

STEP 1 - Unplug ECU connectors

STEP 2 - Remove ECU air pipes

STEP 3 - Remove plug and O-ring from Clutch electrovalves unit

STEP 4 - Remove clutch unit cable clamps

STEP 5 - Remove air supply pipe, unscrew unit and unplug it

STEP 6 - Screw the fixing plate to the "basic housing" / main body

STEP 7 - Remove brass lid and O-ring to drain oil and put it back (35 Nm)

STEP 8 - Remove plug, lid, O-ring and filter from oil pump unit

STEP 9 - Time to remove the shifting module

Gear to remove the pneumatic shifting module: R4 – Direct drive R3 – Overdrive

through diagnosis...

STEP 9 - If there is no way to shift gear (manually or via diagnosis) It is time to remove cover and blow externally!!

STEP 9 - Flip carefully ECU towards to unplug connectors without damaging the circuit boards

STEP 9 - Remove ECU gasket, air supply O-ring and valves unit

Gear to remove the pneumatic shifting module: R4 – Direct drive R3 – Overdrive

...or blowing externally

STEP 9 - Lift carefully the shifting module

STEP 10 - Remove heat exchanger pipes and unscrew oil pump

STEP 10 - Unscrew heat exchanger and remove both components

STEP 11 - Tilt 90º, unscrew and remove the range cover

STEP 11 - Unscrew and remove the range cover Use Jaltest Tool 501051-32 Push the joint for disassembly

STEP 12 - Main shaft pipe disassembly Use Jaltest Tool 501051-09 Pu Unscrew the hexagonal nut

STEP 13 - Remove circlip

STEP 13 - Remove circlip

STEP 14 - Use Jaltest Tools to remove plate and extract screw

STEP 14 - Use Jaltest Tools to remove plate and extract screwUse Jaltest Tools: A) 501051-22 B) 501051-19 C) 501051-23 D) 501051-20 E) 501051-21 F) 501051-25

STEP 14 - Use Jaltest Tools to remove plate and extract screw

STEP 15 - Uncrew and remove secundary shaft plate

STEP 16 - Remove oil pump axle Use Jaltest Tools: 501051-19 501051-22 501051-23 501051-25

STEP 16 - Remove oil pump axle

STEP 17 - Remove oil pump gear

STEP 18 - Remove main shaft output plate

STEP 18 - Clearance test: 0.05 mm

STEP 19 - Tilt 180º and remove clip, pipe, O-rings and clamps

STEP 20 - Remove pneumatic clutch actuator

STEP 21 - Remove transmission brake air pipe

STEP 22 - Remove transmission brake cover and discs/plates

STEP 23 - Unscrew and remove clutch bell

STEP 24 - Remove racor and magnet

STEP 25 - Remove axles

STEP 25 - Remove axles Check state of external rings

STEP 26 - Check marks when there are safety pins

STEP 27 - Check overflow valve and suction pipe

STEP 28 - Check axial clearance after spin 20 times

STEP 29 - Check wheel sensor wearing (under 0.4 mm)

STEP 30 - Fill with oil and check level

Axles disassembly

Axles disassembly

STEP A - Main axle disassembly

STEP B - Main axle disassembly

STEP C - Main axle disassembly

STEP D - Main axle disassembly

STEP E - Main axle disassembly

STEP F - Main axle disassembly

STEP G - Main axle disassembly

Thanks for your attention