05:01-04

Issue 1

Gearbox
GRS890
GRS900
GRS920
GRSH900
GRSO900
Shafts
Work Description

1 714 660

Scania CV AB 2005, Sweden

en

Contents

Contents

Input shaft

Exploded view drawings .......................................... 3

Dismantling .............................................................. 4
Assembly .................................................................. 7

Mainshaft

Exploded view drawing .......................................... 10

Dismantling ............................................................ 12
Renewing bearing races for splitter gearwheel....... 15
Assembly ................................................................ 17

Layshaft

Exploded view drawing .......................................... 24

Dismantling ............................................................ 25
Assembly ................................................................ 29

Specifications

Materials ................................................................. 33
Tightening torques .................................................. 33

Scania CV AB 2005, Sweden

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Input shaft

Input shaft
Exploded view drawings
GRS890, GRS/GRSH900

4
5
3

1
2
3
4
5
6
7
8
9

Shaft
Snap ring
Bearing
Gear
Needle bearing
Sealing ring
Piston ring
Spacing ring
Pipe

1
2
3
4
5
6
7
8

Shaft
Snap ring
Bearing
Gear
Needle bearing
Sealing ring
Piston ring
Pipe

136 218

GRS920, GRSO900
7

4
5
3

136 219

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Scania CV AB 2005, Sweden

Input shaft

Dismantling
Special tools
Description

87 596

Slide hammer

99 136

Hollow drift

99 141

Support ring

Illustration

Tool board
D2

87 596

00 1610

Number

P1

00 1622

99 136

P1

00 1623

99 141

Other tools
Description

587 312

Snap ring pliers

Illustration
587 312

111 445

Number

Scania CV AB 2005, Sweden

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Input shaft

1 Remove the two piston rings by hand.

Earlier gearboxes may have a spacing ring
between the piston rings.

2 Remove the snap ring. Use snap ring pliers

587 312. It may be necessary to tap the
bearing inner race with something first, such
as a drift and hammer.

3 Place the shaft on hollow drift 99 136 and

support ring 99 141. Press out the bearing
and gear. Place something soft underneath
to protect the shaft when it comes loose.

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Scania CV AB 2005, Sweden

Input shaft

4 Remove the bearing and the gear. Remove

the bearing shells.
If the input shaft is the old type, i.e. with the
oil pipe pressed into the input shaft, remove
as follows.

5 Tap the oil pipe using an M10 pilot tap.

6 Pull out the oil pipe using an M10 bolt with

welded-on washer and slide hammer
87 596. Clean the oilway.

Scania CV AB 2005, Sweden

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Input shaft

Assembly
Special tools
Description

98 224

Pressplate

98 334

Counterholding tube

98 450

Shank

Illustration

Tool board
G1

98 224

110 065

Number

G3

110 120

98 334

00 1633

R2, AD2, AM1

98 450

Assembly drift

99 136

Hollow drift

99 141

Support ring

G1

98 636

110 815

98 636

P1

00 1622

99 136

P1

00 1623

99 141

Other tools
Description

587 312

Snap ring pliers

Illustration
587 312

111 445

Number

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Scania CV AB 2005, Sweden

Input shaft

If the input shaft is the old type, i.e. with the oil
pipe pressed into the shaft, fit as described in
steps 1-2.
1 Place the shaft in pressplate 98 224.
2 Press in the oil pipe using shank 98 450.
Press in the pipe so that it protrudes at least
21.5 mm (dimension A). Check that the
lubricating holes are clear. The pipe must
not be upset.

3 Fit the bearing shells and the gear with the

splines downwards.

4 Press on the bearing using counterholding

tube 98 334 and assembly drift 98 636.

Scania CV AB 2005, Sweden

05:01-04

Input shaft

5 Fit the snap ring using snap ring pliers

587 312. Select a snap ring which provides
the least possible clearance between the ring
and bearing. Check that the snap ring goes
down into the groove.

6 Place the shaft on hollow drift 99 136 and

support ring 99 141. Press the bearing
against the snap ring using a press force of
70 kN max. (7 tonnes).

7 Fit the two piston rings. Earlier versions

also have a spacing ring between the piston
rings.

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Scania CV AB 2005, Sweden

Mainshaft

Mainshaft
Exploded view drawing

10

Scania CV AB 2005, Sweden

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Mainshaft

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Mainshaft
Bearing
Nut
Roller bearing
Spacing ring
Shim
Gear
Gear
Needle bearing
Gear
Snap ring
Needle bearing
Gear
Slide bearing
Driver
Coupling sleeve
Gear
Slide bearing
Slide bearing
Nozzle
Shim
Spacing ring
Shift sleeve
Snap ring
Sun wheel
Spacing washer
Shim
Nut

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29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56

Cone
Driver
Compression spring
Plunger
Clevis pin
Shift sleeve
Latch cone
Cone
Synchromesh cone
Driver
Compression spring
Plunger
Clevis pin
Shift sleeve
Latch cone
Coupling disc
Spring pin
Snap ring
Synchromesh
Intermediate cone
Latch cone
Driver plate
Compression spring
Plunger
Clevis pin
Washer
Shift sleeve
Driver

Scania CV AB 2005, Sweden

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Mainshaft

Dismantling
Special tools
Number

Description

Illustration

87 237

Support drift

98 322

Lifting handle

98 575

Support drift

99 136

Hollow drift

99 140

Support ring

99 202

Split support ring

Tool board
G2
G2

109 805

98 322

G2

00 1621

98 575

P1

00 1622

99 136

P1

111 007

99 140

P1

111 022

99 201

Other tools
Description

587 318

Puller plate

587 319

Puller

587 600

Socket

Illustration

114 693

Number

D
Di

00 1890

12

Scania CV AB 2005, Sweden

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Mainshaft

1 Pull off the front bearing. Use support drift

87 237, puller plate 587 318 and puller
587 319.

WARNING!

Wear protective goggles. There is a risk

of flying fragments if the bearing breaks.

2 Remove the round nut, use socket 587 600.

3 Fit lifting handle 98 322 and lift the shaft

onto the press.

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Scania CV AB 2005, Sweden

13

Mainshaft

4 Lower the shaft into hollow drift 99 136.

When the shift sleeve is down in the hollow
drift, fit the split support ring 99 202. Centre
carefully. Place, for example, a rubber cloth
in the drift to cushion the fall.

99 202
99 136

133 794

5 Press out the rear bearing, reverse shaft gear,

crawl and first gears. Protect the ends of the
shaft using support drift 98 575. Remove the
bearing, gears and synchromesh assembly.
Keep the synchromesh assembly as a unit.
Mark the parts and place the assembly to
one side.

98 575

6 Turn the shaft and place it in hollow drift

99 136. Use support ring 99 140. Protect the
ends of the shaft using support drift 98 575.
7 Press out the shaft. Remove the second gear
and splitter gear with their corresponding
synchromesh assembly. Mark the splitter
gearwheel so that it faces in the same
direction during assembly. Keep the
synchromesh assembly as a unit. Mark the
parts and place the assembly to one side.

14

Scania CV AB 2005, Sweden

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Mainshaft

Renewing bearing races for splitter gearwheel

Special tools
Description

87 446

Drift

87 758

Drift

Illustration

Tool board
AD2

87 446

00 1581

Number

G1

00 1611

87 758

Other tools
Description

587 316

Counterhold

587 530

Puller

Illustration

115 110

114 058

Number

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Scania CV AB 2005, Sweden

15

Mainshaft

1 Mount the gearwheel in a vice with soft

jaws. Use puller 587 530 and counterhold
587 316 to pull out one bearing race. Use a
separator plate made of e.g. aluminium
sheet.

2 Press out the other bearing race using drift

87 758.

3 Press in new bearing races using drift

87 446.

16

Scania CV AB 2005, Sweden

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Mainshaft

Assembly
Special tools
Description

Illustration

87 089

Drift

87 089

87 550

Drift

87 550

87 932

Drift

88 292

Pull rod

98 075

Dial gauge

Tool board
AM2, D3

110 283

Number

00 1628

AD2

D3, G1

00 1636

87 932

G2
00 1848

88 292

D2

98 075

0
90

10

10

90

80

20

20

80

15
30

5
10

70

70

30
40

60

60

40

50

00_1637

50

98 568

Drift

98 575

Support drift

98 575

99 127

Drift

99 127

99 136

Hollow drift

AM1

00_1618

98 568

00 1621

G2

00 1629

AM1

P1

00 1622

99 136

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Scania CV AB 2005, Sweden

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Mainshaft

Description

99 140

Support ring

99 190

Drift

99 191

Drift

99 199

Counterhold

Illustration

Tool board
P1

99 140

111 007

Number

G4

00 1638

99 190

G4

109 785

99 191

99 199

111 021

G4

Other tools
Description

Illustration

587 250

Indicator stand with magnetic

base

587 600

Socket

102350

Number

D
Di

00 1890

1 Fit the needle bearing.

2 Fit the second gear with the spline flange
upwards.

18

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Mainshaft

05_3289

3 Fit the synchromesh assembly for second

and third gears with the longer neck of the
driver downwards. Guide onto the splines
and press if necessary.

4 Press one bearing onto the splitter

gearwheel, use drifts 99 190 and 99 191.

5 Fit the spacing ring first and then the shims.

When measuring the clearance, you should
start with too much clearance. Therefore fit
one shim more than before.

6 Fit the splitter gearwheel. Fit it onto the

splines on the synchromesh cone.

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Scania CV AB 2005, Sweden

19

Mainshaft

7 Press on the other bearing using drift 99 190

and 99 191. Rotate the gear while pressing.
Stop pressing if it is hard to rotate the wheel
and change to a thicker shim. See step 11.

8 Fit the round nut. Use counterhold 99 199,

pull rod 88 292 and socket 587 600.
Tightening torque 400 Nm.

9 Check the splitter gearwheel clearance.

Leave the shaft on counterhold 99 199, or
clamp the shaft in a press with 10 - 20 kN.
Fit dial gauge 98 075 and indicator stand
587 250.
10 Rotate the gear a few turns, always in the
same direction. Prise the gear upwards using
two screwdrivers. Rotate the gear and
perform at least three measurements, mark
the gear so that the measurements are
carried out at the same position. Take the
average. Correct clearance: 0.03 - 0.09 mm.

20

Scania CV AB 2005, Sweden

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Mainshaft

11 Adjusting the clearance: Press up the shift

sleeve to gear position 3. Place the shaft in
hollow drift 99 136 with support rings
99 140 and press out the bearing using drift
98 575. Fit new shims and begin again from
step 6.

122 564

12 Lock the nut on the two recesses provided

for the purpose and remove counterhold
99 199.

13 Turn the mainshaft over. Use drift 98 568 as

a support under the shaft if the front bearing
is pressed on.
14 Lubricate and fit the needle bearing.

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Scania CV AB 2005, Sweden

21

Mainshaft

15 Line up the synchromesh assembly and

place it in position on the first gear. Then fit
the gear with the synchromesh assembly on
the shaft.

16 Lubricate and press on the inner ring for the

crawl gear needle bearing. Use drifts 87 550
and 99 127. Fit the needle bearing.

17 Fit the crawl gear with the coupling teeth

upwards. Fit the driver, press if necessary.
Use drifts 87 550 and 99 127.

18 Fit the shift sleeve.

22

Scania CV AB 2005, Sweden

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Mainshaft

19 Lubricate and press on the inner ring for the

reverse gear needle bearing. Use drifts
87 932 and 99 127.

20 Fit the reverse gear needle bearing and the

gear with the coupling teeth downwards.

21 Lubricate the rear bearing and press it on

using drift 87 932.

22 Turn the shaft and press on the front

bearing, use drift 87 089.

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Scania CV AB 2005, Sweden

23

Layshaft

Layshaft
Exploded view drawing
All versions of GRS gearboxes have a layshaft
which is designed in the same way, what differs
is, for example, the number of teeth and the
strength of the gearwheels.
1
2
3
4
5
6
7
8
9
10
11

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Scania CV AB 2005, Sweden

Shaft
Retaining ring
Bearing
Gear
Gear
Spacing sleeve
Gear
Bearing
O-ring
Shim
Retaining ring

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Layshaft

Dismantling
Special tools
Description

98 575

Support drift

98 647

Support drift

99 136

Hollow drift

99 140

Support ring

99 142

Support ring

99 143

Split support ring

99 450

Split support ring

Illustration

Tool board
G2

98 575

00 1621

Number

G2
P1

00 1622

99 136

P1

111 007

99 140

P1

00 1624

99 142

P1

111 008

99 143

128 352

PT1

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Scania CV AB 2005, Sweden

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Layshaft

Other tools
Description

587 312

Snap ring pliers

587 318

Puller plate

587 319

Puller

Illustration
587 312

114 693

111 445

Number

1 Pull off the rear bearing using puller plate

587 318 and puller 587 319. Use support
drift 98 647. If the bearing breaks, split it.

WARNING!

Wear protective goggles.

2 Pull off the front bearing using puller plate

587 318 and puller 587 319. Use support
drift 98 647. Loosen the bearing slightly
first, then grasp it again. If the bearing
breaks, split it.

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Scania CV AB 2005, Sweden

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Layshaft

3 Remove the snap ring. Use snap ring pliers

587 312.

4 Place the layshaft in a press. Centre

carefully.
GRSO900: Press off the layshaft high split
gearwheel. Use hollow drift 99 136 with
split support ring 99 450 and support drift
98 575.
OTHERS: Press off the layshaft low split
gearwheel. Use hollow drift 99 136 with
split support ring 99 143 and support drift
98 575.

GRSO900

Place, for example, a rubber cloth in the

hollow drift to cushion the fall of the shaft
when it drops down.

Other gearboxes

5 Press off the next splitter gearwheel. Use

hollow drift 99 136 with support ring
99 140. Remove the spacing ring.

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Scania CV AB 2005, Sweden

27

Layshaft

6 Press out the second gear. Use hollow drift

99 136, support ring 99 142 and support
drift 98 575.

28

Scania CV AB 2005, Sweden

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Layshaft

Assembly
Special tools
Description

98 575

Support drift

98 638

Assembly drift

99 136

Hollow drift

99 142

Support ring

99 190

Drift

99 191

Drift

99 450

Split support ring

Illustration

Tool board
G2

98 575

00 1621

Number

G3

110 816

98 638

P1

00 1622

99 136

P1

00 1624

99 142

G4

00 1638

99 190

G4
109 785

99 191

128 352

PT1

Other tools
Description

587 312

Snap ring pliers

Illustration
587 312

111 445

Number

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Scania CV AB 2005, Sweden

29

Layshaft

All gears are bonded onto the layshaft. Before

the gears are bonded onto the shaft, the surfaces
must be carefully cleaned with degreasing
solvent. Then use locking compound 584 075
(Loctite 16 705) which is spread evenly over
both surfaces for good adhesion.
IMPORTANT! To guarantee the strength of the
locked joint, the press force when fitting must
reach at least 300 kN (30 tonnes) just before the
gears reach the bottom. If the force is not
attained, the shaft and/or gear should be
scrapped. The reason for this is that if you do
not use the correct locking compound and attain
the correct press force, the gears will rotate on
the shaft.

1 Place the second gear on support ring

99 142 and press in the shaft.
Note: Protect the ends of the shaft using support
drift 98 575. The press force must reach at least
300 kN (30 tonnes) before the gear reaches the
bottom.

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Scania CV AB 2005, Sweden

05:01-04

Layshaft

2 Place the high split gear (low split gear for

GRSO900) on support ring 99 142. Fit the
spacing ring on the shaft and press on the
gear.
Note: Protect the ends of the shaft using support
drift 98 575. The press force must reach at least
300 kN (30 tonnes) before the gear reaches the
bottom.

3 GRSO900: Place the high split gear on

support ring 99 450 and press in the shaft.
OTHERS: Place the low split gear on
support ring 99 142 and press in the shaft.
Note: Protect the ends of the shaft using support
drift 98 575. The press force must reach at least
300 kN (30 tonnes) before the gear reaches the
bottom.

99 450

GRSO900

Other gearboxes

4 Press on the rear bearing. Use drift 99 190

and drift 99 191.

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31

Layshaft

5 Turn the shaft in the press. Fit the snap ring.

6 Place the shaft on drift 99 191. Press on the

front bearing. Use assembly drift 98 638.

32

Scania CV AB 2005, Sweden

05:01-04

Specifications

Specifications
Materials
Sealing agent part No.

584 010

Locking compound

561 200

Tightening torques
Round nut on mainshaft

400 Nm + locking
compound

Lock bolt for reverse gear shaft

50 Nm + locking
compound

Pressure relief valve

45 Nm

Oil pipe

26 Nm

Oil nozzle in shaft

80 Nm

Oil pump bolts

10 Nm

Clutch housing retaining bolts

210 Nm

Support sleeve retaining bolts

26 Nm

Round nut, end yoke

600 Nm

Drain and level plugs

100 Nm

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