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05-52 Retarder R3500, R4100/D

Check - Before starting troubleshooting
General
The same retarder is used in trucks and buses. These troubleshooting instructions apply to
trucks and 2-axle buses. 3-axle buses are covered where applicable.
This description of the retarder troubleshooting procedures should help determine whether
dismantling is necessary.
Spot repairs are often sufficient to make the vehicle operable again.
All work on the retarder must be carried out with the most thorough cleanliness possible.
The retarder is extremely sensitive to impurities.

WARNING!

Hot fluid and coolant can cause personal injury.

This also applies to spot repairs.

Cable harnesses and similar components are often the cause of a fault rather than the
retarder. Therefore, always start by checking for fault codes.
335 769

Troubleshooting the entire auxiliary brake system, i.e. with accompanying controls and
electrical equipment, is achieved using SDP3.
Check the planetary gear function using the SDP3 wizards:
Checks and adjustments > Powertrain > Gearbox > Performance test – retarder. Run the
wizard.
Checks and adjustments > Powertrain > Gearbox > Brake efficiency test. Run the wizard.
Checks and adjustments > Powertrain > Gearbox > Proportional valve check. Run the
wizard.
Test drive
The following applies when test driving the vehicle to check, for example, whether a spot
repair has given the desired result.

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1. Drive the vehicle at a speed of at least 60 kph

2. Select a gear so that the engine speed is at least 1,500 rpm.
3. Brake with the retarder lever in position 5 (maximum position).
If retarder braking capacity is still insufficient, there is still a fault somewhere. Continue
with the troubleshooting as directed.
Renewing components
Use SDP3 for troubleshooting rather than the Workshop Manual in order to avoid
renewing parts that are not defective.
The following components are often renewed despite them not being defective: hand
control assembly, pedal travel sensor and proportional valve.

Check - Hydraulics, air pressure and mechanics of the

retarder.
Tools

Number Designation Illustration Tool board

99 430 VCI2 N/A

142 425

99 654 VCI3 N/A

Pressure gauge 0-10 bar, 5 N/A

2 308 238
m measuring hose
367 007

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Connecting the measuring equipment

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1. Connect the pressure sensor on 2 308 238

Pressure gauge 0-10 bar, 5 m measuring hose
to the valve block.
Information! The retarder may be available in
3 designs: without nipple, with nipple of earlier
design or with nipple of later design.
If the retarder does not have a nipple for
connection, or has a nipple of earlier design, a
nipple of later design must be fitted.

If a new nipple has been fitted, this should

remain in place after completing the work.

321 793
1 2

1. Nipple of earlier design

2. Nipple of later design
320 596

Retarder without nipple

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366 980
Pressure sensor for dial gauge fitted on
the nipple.

2. Use 2 308 238 Pressure gauge 0-10 bar, 5 m

measuring hose to check the air pressure.

3. To check the proportional valve, see the guided

method in SDP3. To measure braking force, see
Measuring braking force.

Measuring braking force

During the test the following values must be checked using SDP3:
• Propeller shaft rotational speed: 700 rpm
• Engine speed: 1,700 rpm
• Oil temperature in the retarder: 60°C-95°C
Information! The oil temperature in the
retarder must not exceed 95°C.

• Coolant temperature: 60 °C + –100 °C

Preparatory operations:
• Check that there is the correct amount of oil in the retarder.

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1.
WARNING!

Lock the wheels using wheel chocks both in

front of and behind the wheels before starting
any work.

2. Remove the propeller shaft from the gearbox.

See 06-01 Propeller shaft .

3. Connect the vehicle to SDP3 using 99 430 VCI2

or 99 654 VCI3.

4. Start the vehicle and release the parking brake.

Select a suitable gear so that the engine speed is
1,700 rpm and the rotational speed of the output
shaft is 700 rpm. Check this with SDP3.

5. Use SDP3 to check the hydraulic oil pressure of

the retarder on braking.

6. Release the parking brake and brake the retarder

in five steps. Make a note of the air pressure
and the hydraulic pressure. Enter the values in
the table. Repeat this procedure three times.
For vehicles with deactivated oil
accumulator: Let the measurement value
stabilise for at least 2 seconds afterwards every
time the retarder braking mode changes.

7. Enter the values on the diagram and check

whether the values fall within the grey area on
the diagram.

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Test 1

Lever 1 2 3 4 5
position

Air
pressure

Oil
pressure

Test 2

Lever 1 2 3 4 5
position

Air
pressure

Oil
pressure

Test 3

Lever 1 2 3 4 5
position

Air
pressure

Oil
pressure

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32

30

28

26

24

22

20

18
Oil pressure

16

14

12

10

0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5 7 7,5 8 8,5 9

321 794
Air pressure

Poor braking effect

Check fault codes and oil level
Action
Check for stored fault codes. Use SDP3 as this makes it possible to see how many times
each fault code has been registered. Then rectify any faults.
No braking effect
Check fault codes and oil level
Action
Check for stored fault codes. Use SDP3 as this makes it possible to see how many times
each fault code has been registered. Then rectify any faults.

Troubleshooting - Oil accumulator

This troubleshooting applies to vehicles with an oil accumulator.
Information! Vehicles with a deactivated oil
accumulator can be identified by a plate sign
with the text DEACTIVATED
ACCUMULATOR hanging on the retarder
cooler's lower right-hand coolant flange.

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1. Check that the retarder oil level is within the

correct range on the oil dipstick.

4
2

The difference between maximum and

minimum levels is approximately 1.3
litres.
1. Maximum level, hot oil
2. Minimum level, hot oil
3. Maximum level, cold oil
4. Minimum level, cold oil

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2. • Pull out the bleed hose (2) from the bracket

on the oil cooler.
• Pressurise the bleed hose (3) from the oil
accumulator with compressed air.
• At the same time, note whether oil is
leaking from the sump bleeder (1). If there
is leakage, this may indicate a leaking oil
accumulator.

420 291
1 2 3

1. Sump bleeder
2. Bleed pipe
3. Bleed hose

3. Check for more leakage than normal from the

bleed pipes (2).
If oil has leaked from the bleed pipes, the fault
may be leakage in the oil accumulator.

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4. Check for more leakage than normal from the

sump bleeder (1).
If oil has leaked from the sump bleeder, the
fault may be leakage in the oil accumulator.

5. To rectify a leaking oil accumulator, see section

Renewing sealing rings on the oil accumulator
plunger (does not apply to vehicles with
deactivated oil accumulator).
For alternative actions for conversion to a
deactivated oil accumulator, see 05-96
Conversion > Conversion of oil accumulator,
retarder.

Renewal - Oil filter, draining and filling the oil

accumulator and checking the oil level.

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Filter renewal
1. Remove the oil plug and drain the oil.

1
R4

M1

309 740
2 3

1. Oil dipstick
2. Oil filter
3. Oil plug
4. Filler nipple

2. Information! Vehicles with a deactivated oil

accumulator can be identified by a plate sign
with the text DEACTIVATED
ACCUMULATOR hanging on the retarder
cooler's lower right-hand coolant flange.

Applies to vehicles with an oil accumulator:

Drain the oil accumulator.
With retarder lever: Drain the oil accumulator
by turning the key to drive mode (pneumatic
system filled to working pressure) and move the
retarder lever between the 0 position and
maximum position several times, waiting for 5
seconds at each end position.
Without retarder lever: Vehicles with an
automatic retarder do not have a retarder lever,
just a switch on the instrument panel. Use SDP3
to drain and fill the oil. See Drainingor Filling
the accumulator tank under Functions, Checks,
Brakes, Retarder.

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3. Applies to vehicles with a deactivated oil

accumulator
With retarder lever: The oil accumulator must
not be drained
of oil.
Without retarder lever: The wizards for
draining in SDP3 are
deactivated.

4. Clean the oil dipstick and filter housing.

1
R4

M1

309 740
2 3

1. Oil dipstick
2. Oil filter
3. Oil plug
4. Filler nipple

5. Remove the filter housing and filter.

6. Fit the filter housing with the filter.

Clean the filter housing, check that the O-ring is
not damaged. Insert a new filter and screw the
filter housing back into place.

7. Renew the seal and fit the drain plug.

Drain plug
25 Nm

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8. Fill with oil.

Fill with oil through the dipstick hole.
Alternatively, the oil may be topped up through 4
the filler nipple (4).

1
R4

M1

309 740
2 3

1. Oil dipstick
2. Oil filter
3. Oil plug
4. Filler nipple

9. Check the oil level.

Check the oil level using the oil dipstick.

Inspection instructions
Oil change
Renew the oil filter when changing the oil. For information about oil volumes and oil
grades, refer to 00:16-15 Fuel, lubricants and fluids.

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Checking the oil level and filling the oil accumulator

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1. Information! Vehicles with a deactivated oil

accumulator can be identified by a plate sign
with the text DEACTIVATED
ACCUMULATOR hanging on the retarder
cooler's lower right-hand coolant flange.

Applies to vehicles with an oil accumulator:

Check the retarder oil level
With retarder lever
• If the accumulator has been drained of oil,
it must be filled up again to obtain the
correct level on the dipstick.
• Fill the oil accumulator by turning the key
to the drive position (compressed air
system filled to working pressure) and
move the retarder lever between the 0
position and maximum position several
times, waiting for 5 seconds at each end
position.
• Fill with a little oil at a time and check the
level with the dipstick.
• Check that the oil dipstick seal is not
damaged and screw it on.
Without retarder lever
• Vehicles with an automatic retarder do not
have a retarder lever, just a switch on the
instrument panel.
• Use SDP3 to drain and fill the oil. See
Drainingor Filling the accumulator tank
under Functions, Checks, Brakes, Retarder.

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4
2

The difference between maximum and

minimum level is approx. 1.3 litres.
1. Maximum level, hot oil
2. Minimum level, hot oil
3. Maximum level, cold oil
4. Minimum level, cold oil

2. Applies to vehicles with a deactivated oil

accumulator:
• With retarder lever: The oil accumulator
must not be filled
with oil.
• Without retarder lever: The wizards for
filling oil in
SDP3 are deactivated.

Draining the oil accumulator on a vehicle with the power

disconnected.

IMPORTANT!

Do not bleed vehicles with a deactivated oil

accumulator.

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Information! Vehicles with a deactivated oil

accumulator can be identified by a plate sign
with the text DEACTIVATED
ACCUMULATOR hanging on the retarder
cooler's lower right-hand coolant flange.

1. Drain the oil, see section Renewing the filter M2

and draining the oil accumulator.

Blow into the drain hose for connection R1 with
compressed air. Repeat a couple of times.

M3

R4
R2 R1
M1
R3

R5
P

11
432 0
Maintenance instructions
Oil change
Renew the oil filter when changing the oil. For more information about oil volumes and
oil grades, see 00:16-15 Fuel, lubricants and fluids
Renewal - Solenoid valve block
1. Remove sensor V97.

2. Pull out the air lines for air drainage from the
bracket in the oil cooler. Unscrew the
connections from the solenoid valve block.

3. Remove the air connection for the compressed

air supply. See 10-75 Pneumatic diagram >
Compressed air lines .

4. Applies to vehicles with an oil accumulator

Remove the solenoid valve block and old O-rings.

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4.1 Fit new O-rings and fit the solenoid valve

block.

5. Applies to vehicles with a deactivated oil

accumulator
Information! Vehicles with a deactivated oil
accumulator can be identified by a plate sign
with the text DEACTIVATED
ACCUMULATOR hanging on the retarder
cooler's lower right-hand coolant flange.

5.1

Remove the solenoid valve block, 2 O-rings and a plug.

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5.2 Information! Ensure that the O-rings and the

plug are in place when the solenoid valve block
is fitted. Grease the O-rings lightly so that they
stay in place.

Fit 2 new O-rings, new plug and solenoid valve

block.

431 641
6. Fit sensor V97.

7. Screw on the air drainage connections and push

the ends in the bracket on the oil cooler.
Fit the air connection for the compressed air
supply. See 10-75 Pneumatic diagram >
Compressed air lines .
M2

M3

R4
R2 R1
M1
R3

R5
P

P=Compressed air supply, R=Air drains,

M=Test connection

Description - Lifting accessory assembly, retarder

Tools

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Tool
Number Designation Illustration
board

99 644 Base bracket F3

323 007
Tool 99 644 fits most gearbox jacks distributed by Scania. If another type of gearbox
jack is used, another base bracket must be used, see tool sheet for 99 645 Base
bracket.

99 645 Base bracket F3

319 428

99 646 Bracket kit F3

323 008

587 313 Gearbox jack N/A

142 734

588 966 Machine lift N/A

336 862

Safety
The lifting accessory is secured to the component as follows.

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323014
30Nm

All screws must be tightened according to Scania’s standard tightening torque, except the
screws for locking the central brackets and base bracket. These should be tightened to
30 Nm.

WARNING!

Never work or go under a vehicle not secured

against falling. There is a serious danger of
crushing.
Both the chassis and moving axle suspension
components must be secured with axle stands to
ensure absolute safety when working under a
raised vehicle.
If the vehicle has air suspension, the air bellows
must be emptied before starting work.
Only move a loaded gearbox jack with the load
in the lowest possible position.
When lowering, make sure that the gearbox
jack/unit or the lifting accessory goes clear of
any obstructions to avoid any damage.
Be aware of the risk of crushing when lowering
the gearbox jack and the lifting accessory.

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Test
Limitations* Maintenance
factor

Maximum load for long

central beam: 800 kg
Check lifting accessories before use for
1.5 static.
damage, deformation and wear.
Maximum load for short
central beam: 800 kg

*The given weights only apply when using 99 644 Base bracket according to the
descriptions in Workshop Manual.
Assembly
Information! References such as front/rear
and right-hand/left-hand are along the gearbox.
The tool is attached to the gearbox with the end
yoke facing the handle for moving the gearbox
jack.

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1. The following parts from 99 646 Bracket kit are 1

used for assembly:

4 5

422 649
3

1. Front sliding bracket

2. Rear sliding bracket
3. Central beam
4. Base bracket
5. Support
6. Adjustable stay
7. Anti-slip device

2. Secure 99 644 Base bracket to 587 313

Gearbox jack or 588 966 Machine lift.

3. Centre the central beam in the base bracket so

that the beam protrudes equally at the front and
at the rear. = =
325 258

4. Position the front sliding bracket edge-to-edge

against the front end of the central beam. The
rear sliding bracket must not be used.
326 206

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5. Fit short adjustable stays on the left-hand and

right-hand sides with anti-slip devices.

326 207
Left-hand adjustable stay

326 208
Right-hand adjustable stay

6. Raise the tool so that the retarder is standing on

the oil plug.

7. Screw the left-hand adjustable stay into place in

the retarder. Use an M10x30 screw in the outer
hole of the heat exchanger.
Screw the right-hand adjustable stay into place
in the retarder. Use an M10x30 screw in the
heat exchanger retaining hole.
326 209

Description - Lifting accessory assembly, oil cooler

Tools

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Tool
Number Designation Illustration
board

99 644 Base bracket F3

323 007
Tool 99 644 fits most gearbox jacks distributed by Scania. If another type of gearbox
jack is used, another base bracket must be used, see tool sheet for 99 645 Base
bracket.

99 645 Base bracket F3

319 428

99 646 Bracket kit F3

323 008

587 313 Gearbox jack N/A

142 734

588 966 Machine lift N/A

336 862

Safety
The lifting accessory is secured to the component as follows.

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323014
30Nm

All screws must be tightened according to Scania’s standard tightening torque, except the
screws for locking the central brackets and base bracket. These should be tightened to
30 Nm.

WARNING!

Never work or go under a vehicle not secured

against falling. There is a serious danger of
crushing.
Both the chassis and moving axle suspension
components must be secured with axle stands to
ensure absolute safety when working under a
raised vehicle.
If the vehicle has air suspension, the air bellows
must be emptied before starting work.
Only move a loaded gearbox jack with the load
in the lowest possible position.
When lowering, make sure that the gearbox
jack/unit or the lifting accessory goes clear of
any obstructions to avoid any damage.
Be aware of the risk of crushing when lowering
the gearbox jack and the lifting accessory.

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Test
Limitations* Maintenance
factor

Maximum load for long

central beam: 800 kg
Check lifting accessories before use for
1.5 static.
damage, deformation and wear.
Maximum load for short
central beam: 800 kg

*The given weights only apply when using 99 644 Base bracket according to the
descriptions in Workshop Manual.
Assembly
1. The following parts from 99 646 Bracket kit are
used for assembly:
2
4

7
1

b323928
5

1. Front sliding bracket

2. Rear sliding bracket
3. Central beam
4. Base bracket
5. Support
6. Adjustable stay
7. Anti-slip device

2. Screw 99 644 Base bracket onto 587 313

Gearbox jack or 588 966 Machine lift.

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3. 1. Position the sliding bracket at the edge of

the central beam front end.
2. Slide the central beam rearwards until the
sliding bracket is edge-to-edge with the
base bracket.
3. Screw the base bracket and sliding bracket
into the central beam.
4. Screw 1 longer adjustable stay into place
using a sliding bracket.

334 281
4. Place the oil cooler on the sliding bracket. Then
screw the oil cooler into place in the adjustable
stay using an M10X20 mm flange screw or
screw with washer as illustrated.

334 282

Renewal - Oil cooler

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Remove the oil cooler

R4 R4

M1 M1

1 2

1. Oil drainage 2. Coolant drainage

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1.
WARNING!

Take care with hot fluid and coolant! Wear

protective gloves and goggles.

Old design: Draining the oil using the oil drain

plug (1). Drain the coolant using coolant
drainage (2). Drain the coolant pipe between the
engine and retarder inlet at its lowest point.
Newer version: Draining the oil using the oil
drain plug (1). Drain the coolant by opening the
flange pipe. Drain the coolant pipe between the
engine and retarder inlet at its lowest point.

2. Cut the cable ties securing the air lines and

electrical cables to the bracket on the oil cooler.

3. Old design: Undo the clamps securing the pipe

bends. Remove them from the oil cooler and
bend the hoses to one side.
Newer version: Undo the flange screws
securing the pipe bends. Remove them from the
oil cooler and bend the hoses to one side.

4. Remove the lower retaining screws and suspend

the bracket and sensor to one side.

5. Attach the oil cooler to the lifting accessory.

See Description – Lifting accessory assembly,
oil cooler. Insert one of the attaching screws at
the arrow so that the cooler does not fall
sideways.

6. Remove the upper retaining screws and remove

the oil cooler.

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Fit the oil cooler

R4

M1

B
387 215

1. Fit new O-rings.

2. Attach the oil cooler to the lifting accessory.

See Description – Lifting accessory assembly,
oil cooler.

3. Screw one guide pin onto the upper bracket and

one onto the lower bracket. The guide pins are
made from 10 x 120 mm screws.

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4. Lift the oil cooler into position and screw one

retaining screw into the upper bracket. Remove
the upper guide pine and screw on the other
screw.

5. Remove the lower guide pin and fit a new

O-ring. Place the sensor bracket in position and
fit the lower retaining screws.

6. Fit the horizontal part of the retarder

ventilation, where applicable, using cable ties.

7. Fit new O-rings and fit hoses onto the pipe

bends.

8. Old design: Screw on the pipe bends with the

clamps at the points indicated by an (A) in the
illustration.
Newer version: Screw on the pipe bends using
flange screws.

9. Secure the electrical cables and compressed air

lines using cable ties onto the bracket on the oil
cooler.

10. Push the drain hoses from the solenoid valve

block into bracket (B).

11. Old design: Refit the coolant drain plugs.

Newer version: Fit the flange pipe.

12. Refit the oil drain plug.

Drain plug
25 Nm

13. Fill with coolant.

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14. Bend back the hose and fill with oil. See
Renewal – Renewing the oil filter, draining and
filling the oil accumulator and checking the oil
level.

15. Check the levels after a test drive.

Removal - Retarder
Tools

Number Designation Illustration Tool board

98 257 Support drift AM2

142 050
99 001 Threaded adapter H1

142 083

Hydraulic hole cylinder, H1

99 003
16t 321 204

The tool is used together with 99 004 Pneumatic hydraulic pump.

99 004 Pneumatic hydraulic pump H1

321 205

99 011 Threaded bush H1

142 091

99 012 Threaded spindle M20 AD/AS3, H1

321 206

99 497 Puller G2
143 075

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1. If the hidden reductant tank prevents access:

Remove the reductant tank. See 03-26 Exhaust
gas aftertreatment > Reductant tank.

2.
WARNING!

Beware of hot oil! Wear protective gloves and

goggles.

Drain the oil from the gearbox.

3. Drain the oil from the retarder. See Renewal –

Renewing the oil filter, draining and filling the
oil accumulator and checking the oil level.

4. Drain the coolant from the retarder. See

Renewal – Oil cooler.

5. Information! Cover the hole in the gearbox

when the hydraulic pump has been removed so
that dirt cannot get into the gearbox.

If the vehicle has dual-circuit steering: Detach

the hydraulic pump.

Removing the solenoid valve block

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M3

R4

R2 R1
M1
R3
R5

1. Cut the tie straps holding the electrical cables

and compressed air lines onto the bracket on the
oil cooler.

2. Remove the screws and suspend the solenoid

valve block to one side.

Removing the end yoke

A B

99 003 99 001
99 497
99 012 99 011

99 497

99 004

98 257
M3

R4

R2 R1
M1
R3
R5

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1. Remove the nut using 99 497 Pullersplined

socket 98 765.

2. Pull off the end yoke as indicated in alternative

A or B. For alternative B, use:
• 99 001 Threaded adapter
• 99 003 Hydraulic hole cylinder, 16t
• 99 004 Pneumatic hydraulic pump
• 99 011 Threaded bush
• 99 012 Threaded spindle M20
• 98 257 Support drift
• 99 497 Puller

Removing the oil cooler

Remove the oil cooler. See Renewal – Oil cooler.
Removing the retarder, general

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1. Remove the upper nuts holding the coolant pipe

onto the bracket.

2. Remove the brackets for the coolant pipes.

3. Remove the connection for road speed sensor

(A).

4. Remove the air duct.

5. Remove three of the five screws around the

output shaft.

6. Remove all screws marked with an arrow.

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Removing the retarder from above using the lifting accessory

1. Hook into the retarder lifting eye.

2. Remove the remaining two screws around the

output shaft.

IMPORTANT!

Do not shake the retarder when it is pulled out,

because this would damage the rotor shaft
bearing.

3. Lower the retarder.

Removing the retarder from below

1. Fit the lifting accessory on the retarder. See
Description – Lifting accessory assembly,
retarder.

2. Remove the remaining 2 screws around the

output shaft.

IMPORTANT!

Do not shake the retarder when it is pulled out,

because this would damage the rotor shaft
bearing.

Renewal - Bearing on rotor shaft

Tools

Number Designation Illustration Tool board

87 237 Support drift G2

141 882

98 257 Support drift AM2

142 050

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Number Designation Illustration Tool board

2 587 982 Puller plate, 12-75 mm XA1

401 100
2 587 985 Puller plate, 30-155 mm XA1

401 100
2 587 987 Bearing puller, 55-140 mm XA1

401 102

2 587 989 Bearing puller, 85-295 mm XA1

401 102

If only the rotor shaft cylindrical bearing needs renewing the retarder does not need to be
dismantled.
To renew the bearing outer race with rollers refer to the work description for the gearbox.

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Removal
1. Remove the retarder. See section Removal –
Retarder.

2. Tighten the nuts on 2 587 982 Puller plate, 12-

75 mm so that the puller has a good grip behind 2 587 987
the race. Pull out the race a little and tighten the
nuts again, but not so much as to damage the
rotor shaft. Use 87 237 Support drift and
2 587 987 Bearing puller, 55-140 mm.
87 237

2 587 982

394 995
Fitting
1. Tighten the nuts on 2 587 985 Puller plate, 30-
155 mm so that the puller has a good grip 2 587 989 2 587 985
behind the gear, but not so much that the
retarder housing receives pressure marks. Use
98 257 Support drift and 2 587 989 Bearing
puller, 85-295 mm.
98 257

394 996

2. Refit the retarder. See the section Fitting –

Retarder.

Repair - Retarder
Tools

Number Designation Illustration Tool board

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Number Designation Illustration Tool board

87 237 Support drift G2

141 882
87 504 Drift AM1, R1

141 996
98 364 Assembly drift R1

142 052
98 550 KM socket, 52.6 mm, 1/2" AD/AS3, G2, G3

140 361
99 147 Drift R3

142 152

99 243 Drift 321 234

G3

99 436 Assembly tool AD/AS5

142 428

99 438 Assembly tool AD/AS5

142 433

99 471 Adapter for drift 99 147 R3

142 463

99 550 Assembly tool G2

143 117

99 564 Assembly tool G2

144 454

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Number Designation Illustration Tool board

2 587 983 Puller plate, 22-115 mm XA1

401 100
2 587 987 Bearing puller, 55-140 mm XA1

401 102
2 730 879 Press drift for sealing ring N/A

406 503

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Dismantling the retarder

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1. • Place the retarder on a workbench.

• Remove the bleed pipe.
• Remove the screws marked in black; see
illustration.
• Remove the sleeve at the arrow; see
illustration.
• Lift away the oil pan cover.

1 2 3 4

1. Bearing housing
2. Retarder housing
3. Valve housing
4. Oil pan cover

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2. Leave the air pistons for the control valve A and

safety valve B in the oil sump cover unless oil
has leaked past them.
• If piston A is not sealed, oil will run out of
the air drain marked R2 on solenoid valve
block V97.
• If the piston B is not sealing, oil will run
out of the air drain marked R4 on solenoid
valve block V97.
Applies to vehicles with an oil accumulator:
Remove the oil accumulator O-rings.
Keep the guide sleeves if they are loose.
Applies to vehicles with a deactivated oil
accumulator:
Keep the guide sleeves if they are loose.
M2

A
B

M3

R4
R2 R1
M1
R3

R5
P
R4

R2

3. Applies to vehicles with an oil accumulator

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3.1 • Leave the piston in the accumulator

cylinder if the piston seal is not to be
renewed. Carefully remove the oil
accumulator so that the spring does not
damage the cylinder walls. Remove the
spring and O-ring.
• If no oil has leaked via the oil accumulator
operating air drain, connection R1 on
solenoid valve block V97, the piston
should not be removed from the cylinder.
• Remove the valves and their springs.
• Mark the oil pump so it can be refitted in
the same position. Remove the oil pump.

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4 6

7 10

8
3

2 9

1. Oil accumulator
2. Oil accumulator intake
valve
3. Oil accumulator outlet
valve
4. Control valve
5. Intake check valve
6. Safety valve
7. Check valve to provide oil
flow to reduce slip losses
8. Oil pump
9. Check valve for reducing
pump pressure

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10. Outlet check valve

4. Applies to vehicles with a deactivated oil

accumulator
Information! Vehicles with a deactivated oil
accumulator can be identified by a plate sign
with the text DEACTIVATED
ACCUMULATOR hanging on the retarder
cooler's lower right-hand coolant flange.

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4.1 Carefully remove the oil accumulator so that the

spring does not damage the cylinder walls.
• Remove the spring and O-ring. Do not
remove the piston seals.
• Remove the valves and their springs.
• Mark the oil pump so it can be refitted in
the same position. Remove the oil pump.

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3 5

6 9

7
2

4
1 8

431 640
1. Oil accumulator intake
valve
2. Oil accumulator outlet
valve
3. Control valve
4. Intake check valve
5. Safety valve
6. Check valve to provide oil
flow to reduce slip losses
7. Oil pump
8. Check valve for reducing
pump pressure
9. Outlet check valve

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5. • Remove the screws and guide pins (if they

are loose).
• Lift off the valve housing.
• Remove the gasket and guide pins (if they
are loose).

6. Clean oil residues and dirt.

7. Clamp the gear in a vice with soft jaws and

unscrew the nut using 98 550 KM socket, 52.6
mm, 1/2". 98 550

8. Press out the rotor shaft:

• Lift the retarder housing over to a press.
• Place the housing as illustrated.
• Place a soft material underneath so that the
shaft is not damaged when it is pressed out
using 99 438 Assembly tool from 99 436
Assembly tool. 99 438

• Lift the housing over to a workbench.

• Remove the stator, rotor and bronze ring
with O-ring.
148 528

Renewing the bearing race on the rotor shaft

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Refer to the work description for the gearbox for renewing the bearing outer race with
rollers.

2 587 987

87 237

2 587 983

394 994

1. Tighten the nuts on 2 587 987 Bearing puller,

55-140 mm so that the puller has a good grip
behind the bearing race.

2. Pull the bearing race off slightly and tighten the

nuts again but no so much that the shaft is
damaged.

3. Pull off the bearing race using 87 237 Support

drift and 2 587 983 Puller plate, 22-115 mm.

4. Place the shaft on the press bench and press on

a new bearing race.

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Renewing the bearing in the stator

87 504

98 364

1. Press out the bearing using 87 504 Drift and

98 364 Assembly drift.

2. Press in a new bearing.

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Renewing the seal in the retarder housing

1. Remove the retaining ring.

404 964
2. Turn the retarder housing over and tap out the
seal using a drift.

305 134

3. Clean the sealing area.

4. Fit the guide sleeve from 2 730 879 Press drift

for sealing ring on the retarder housing.
404 963

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5.
IMPORTANT!

Apply a thin film of retarder oil (at least 3 ml)

all the way around the sealing ring.

IMPORTANT!

Do not remove the seal from the protection

sleeve.

• Position a slightly-lubricated retaining ring

(1) on the press drift (2) from 2 730 879
Press drift for sealing ring.
• Fit the sealing ring on the press drift (2).

2
404 962

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6.
IMPORTANT!

When the seal has been pressed into place,

maintain the pressure with the press for at least
3 seconds so that the seal has time to settle in
the retarder housing.

Fit the press drift and the sealing ring to the

guide sleeve. Then carefully press the sealing
ring and retaining ring down (max.: 15 kN) in

404 961
the retarder housing.

7. Check that the retaining ring is in place by

carefully tapping it using a drift.

404 960

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Applies to vehicles with an oil accumulator

1. Fit the oil accumulator pipe if it has been
removed. Torque tighten the banjo screw.

Oil pipe from accumulator, banjo screw

42 Nm

305 142
Assembling the retarder housing, rotor, rotor shaft and stator

IMPORTANT!

There are two different types of rotor shaft, one

with a gear ratio of 3.04 and one with a gear
ratio of 3.26.
The rotor shafts can become mixed up: the 3.26
one can be assembled with the gear that has a
gear ratio of 3.04, resulting in a breakdown!
To prevent them from becoming mixed up, the
rotor shafts have been given a different
appearance; the rotor shaft with a gear ratio of
3.26 has two turned grooves. See illustration.
The 3.04 rotor shaft cannot be assembled with
the 3.26 gear.

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321 039
Rotor shaft with gear ratio of 3.26 with
two grooves

321 038

Rotor shaft with gear ratio of 3.04

without grooves
321 036

Incorrect. Rotor shaft with gear ratio of

3.26 and gear with gear ratio of 3.04
321 037

Correct. Rotor shaft with gear ratio of

3.04 and gear with gear ratio of 3.04

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IMPORTANT!

When the retarder housing has been lifted into

position on the shaft, the shaft must be kept still
until the rotor and stator are in position, so that
the seal is not damaged.

1 2
99 564 99 564

45 mm

99 564

80 mm
374 825

IMPORTANT!

Applies to freewheeling retarder:99 564

Assembly tool must be fitted tightly against the
shaft, otherwise the seal may be damaged
during installation.

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1. Place the rotor shaft on the press table and fit

99 564 Assembly tool on the shaft. Apply oil to
the tool.

2. Place a support, 45 mm thick, on the press

bench and carefully fit the retarder housing onto
the shaft. Adjust the thickness of the support, if
necessary, so that the retarder housing is level.
Remove the tool with the protection sleeve.

3. Applies to freewheeling retarder: Place an 80

mm thick support on the press bench and
carefully thread the retarder housing onto the
shaft. Adjust the thickness of the support, if
necessary, so that the retarder housing is level.
Remove the tool with the protection sleeve.

4. Fit an oiled O-ring onto the bronze ring. Fit the

bronze ring into the housing. The O-ring will be
visible.

148 786
5.
WARNING!

Use protective gloves!

ON

OFF
148 525

Heat the rotor to approx. 100°C.

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6. Lubricate around the splines with oil.

148 524
7. Press the rotor onto the shaft using 99 243 Drift.

99 243

148 526

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8. Press on the lower race using 99 243 Drift. Fit

the stator and bearing. Align the stator with the
arrow and carefully press the parts together. Fit
the washer and screw on the nut.
1 2

99 243

45 mm

99 243

80 mm

374 824

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9.
IMPORTANT! 180 Nm 98 550

When moving to a vice: Do not turn the retarder

housing so that the rotor shaft moves axially, as
this may damage the seal.

Secure the retarder housing in a vice with soft

jaws. Torque tighten to 98 550 KM socket, 52.6
mm, 1/2".

Retarder shaft, lock nut

180 Nm

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Renewing the sealing rings on the oil accumulator piston

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1.
IMPORTANT!

The sealing ring must be pressed straight down

when it is fitted on the piston. There is a high
risk that it will be damaged if it is tilted when it
is pressed down.

IMPORTANT!

Check that the sealing rings are straight in the

groove.

Press the piston out of the cylinder and remove

the sealing rings.
1. Oil a new sealing ring and press it straight
down on the piston using 99 550 Assembly
tool
2. Carefully insert the piston into the cylinder
and press it down to the bottom.
3. Position 99 147 Driftand 99 471 Adapter
for drift 99 147on a workbench.
4. Turn over the cylinder, fit it over the tools
and press it down so that it rests on the
workbench. Oil the sealing ring groove.
5. Press the other sealing ring straight down
on the piston.
6. Lift the cylinder with the piston off the
tools, oil the sealing ring and carefully
press the piston down in the cylinder.

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1 2

99 550

4 5

99 471

99 147

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Assembling the retarder housing and valve housing

1.
IMPORTANT!

The cylinder must be pressed straight down. Do

not press with such force that the cylinder is
damaged.

Press on the cylinder for the outlet check valve

if it was removed.
Screw on the valve sleeves for the control and
safety valves if they were removed and torque
tighten them.

Valve seat (2 off)

77 Nm

Fit the guide sleeves in the retarder housing and

fit the gasket.
Fit the valve housing.

77 Nm

2. Screw on the housing parts and tighten the bolts

by hand. Fit the two guide sleeves.

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Applies to vehicles with an oil accumulator

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1. • Fit a new O-ring, fit the spring and

carefully fit the accumulator with piston on
the spring.
• Assemble the pump gear according to the
marks made earlier.
• Fit valves and springs.

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4 6

7 10

8
3

2 9

1. Oil accumulator
2. Oil accumulator intake
valve
3. Oil accumulator outlet
valve
4. Control valve
5. Intake check valve
6. Safety valve
7. Check valve to provide oil
flow to reduce slip losses
8. Oil pump
9. Check valve for reducing
pump pressure

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10. Outlet check valve

Assembling the valve housing and oil pan cover

1. Fitting the air pistons for the control and safety
valves:
• Oil the sealing lips and cylinders.
• Press the pistons straight down using a
sleeve. The pistons should be pressed right
down to the bottom.

1 2 90
° °

90

2. Applies to vehicles with an oil accumulator:

Apply grease in the groove for the oil
accumulator O-ring in the oil pan cover and fit a
new O-ring in the groove.
Applies to all vehicles:
• Fit and new gasket and carefully fit the oil
pan cover on the valve housing.
• Fit all the oil pan cover bolts and tighten
them by hand.

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3. Torque tighten the screws according to the

numbering.
Check tighten screws 5, 6 and 7.
Tighten screws 1-4 in accordance with the
numbering.
Apply grease to the hole for the spacing sleeve
at the arrow and insert the sleeve.

11
10

4
2

3 1

6 8

14 15
18
16
17 13 12

19

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4. Fit the bleed pipe.

Fitting - Retarder
Tools

Number Designation Illustration Tool board

99 005 (–1) Pusher adapter H1

142 087
The tool is included in 99 005 Pusher adapter

87 095 Guide pins, M10 D4, G2

141 863
Pull rod, 1,000 mm, G2
88 292
Ø25mm
142 026

98 765 KM socket, 70.2 mm, 3/4" G2

140 660

99 005-1

99 005 Pusher adapter 99 005-3 H1

87 184

99 005-2

99 005-4
319 518

99 010 Bush H1
142 090

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Number Designation Illustration Tool board

99 012 Threaded spindle M20 AD/AS3, H1

321 206
99 040 Pusher adapter H1

142 098
2 426 160 Counterhold G2

374 794

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1. Fit the guide pin and fit a new gasket.

2. Screw on 2 pcs87 095 Guide pins, M10 as

illustrated.

87 095

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3.
IMPORTANT!

The retarder must be pushed in carefully so that

the bearing is not damaged. Check that the
space between the retarder and gearbox is
parallel both horizontally and vertically the
whole time so that the bearing inner race on the
rotor shaft is aligned correctly in the bearing in
the gearbox. If there is resistance, then the
cause must be investigated. Do not shake the
retarder when it is pushed into position.

Lift the retarder into place.

The retarder can be lifted into place from above
by hooking it into the lifting eye or from below.
When fitting from below, see Description –
Lifting accessory assembly, retarder.

4. Remove the guide pin on the output shaft and

tighten the screws around the output shaft and
torque tighten them diagonally.

Output shaft, screws

25 Nm

5. Remove the lifting accessories and remove the

other guide pin.

6. Fit the spacing sleeve in the hole immediately

below the upper oil cooler bracket and screw on
all screws marked with an arrow and torque
tighten them diagonally.

Output shaft, screws

25 Nm

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7. Screw the coolant pipe bracket into place.

Bracket, coolant pipe

25 Nm

8. Tighten the screws around the output shaft, the

coolant pipe screws and all arrowed screws
crosswise. Check-tighten the first five screws to
be tightened.

Output shaft, screws

50 Nm

9. Screw the coolant pipe onto the bracket.

10. Screw on the road speed sensor.

11. Fit the air duct.

12. If the concealed reductant tank has been

removed: Fit the reductant tank. See 03-26
Exhaust gas aftertreatment > Reductant tank.

Fitting the end yoke

2 426 160

99 005-1
99 012
99 012
98 765

99 010
99 040
99 040
600 Nm
384 433

88 292

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Vehicle/engine type: L, P, G, R, S series truck (2016- )

1. Fit the end yoke with the tools as illustrated.

Use:
• 99 005 (–1) Pusher adapter
• 99 010 Bush
• 99 012 Threaded spindle M20
• 99 040 Pusher adapter
• 88 292 Pull rod, 1,000 mm, Ø25mm
• 98 765 KM socket, 70.2 mm, 3/4"
• 2 426 160 Counterhold

2. Fit a new nut, torque tighten the nut and lock it

by upsetting it in the two recesses in the end
yoke.

End yoke, round nut

600 Nm

Fitting the solenoid valve block and oil cooler

1. Fit new O-rings and screw on the solenoid
valve block.

10/10/2023 ([Link]) [Multi_Authorized] © Scania CV 80 of 81

 Multi Client User
Vehicle/engine type: L, P, G, R, S series truck (2016- )

Applies to vehicles with a deactivated oil accumulator

Information! Vehicles with a deactivated oil
accumulator can be identified by a plate sign
with the text DEACTIVATED
ACCUMULATOR hanging on the retarder
cooler's lower right-hand coolant flange.

1.

431 641
2. Fit 2 new O-rings and a new plug. Fit the
solenoid valve block.

3. Fit the oil cooler. See Renewal – Oil cooler .

4. Fill with coolant and oil. See Renewal –

Renewing the oil filter, draining and filling the
oil accumulator and checking the oil level .

10/10/2023 ([Link]) [Multi_Authorized] © Scania CV 81 of 81