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VOLVO TRUCKS (VECV) - Technical Failure Analysis Report

Purpose of TFAR	Approval	Approval / feedback	Warranty	Type of TFAR	Truck Chassis

Subject/Complaint
Clutch Malfunction signal pop on display and gear not shifting.
Report Number	691210-2-2025-70552	Report Date	06-Aug-2025	Prepared By	pkumar11
Dealer ID/Name
Customer Name		Customer Contact Person
Workshop/Site-Location		Customer Contact Number
Chassis Model with Axle Configuration		Body CuM & Application
Chassis No		Reg. Number		Date of Delivery
Date of failure		Repair Order No.		Repair Date
Failure Mileage kms		Age in Months		Engine Hrs.
Function Group		Causal Part No.		Description
Defect Code Group		Defect Code
Spare parts warranty		Spare parts invoice details		Spare parts fitment date*
Spare Parts age in months		Driveline Warranty		GDR No

Repair Estimate Summary

Material Cost		Labor Cost		Other Cost

Road Details

Type of road surface (Asphalt, Soil Gravel, Sharp stones etc.
Dust Condition (Heavy Slight, etc.,)
Approx. Gradient of the Road (required for engine and wheel Hub failures
Undulation on the Road( Heavy,Slight, Lot of pot holes, large Bumps, etc.)
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures

Load Details

Type of load carried		Permitted Technical GCW		GCW during failure

Available information on the load types and GCW's handled by the vehicle earlier which could have caused the failure

Aggregate details

Details of the concerned failed Aggregate ( Engine, Gearbox, Rear Axle, Diffeerential, Rear Axle, Diff. carrier, steering gear, Turbocharger, Superstructure Hydraulic parts etc…)
Aggregate		Aggregate Part No.		Aggregate Sr. No.

Interview with the Driver ( Applicable for all driveline related failures)

Driver Name		Training details on the related variant

Drivers description on the happening of the failure:

Technical Explination of (Dealer comment):

According to complain checked vehicle found clutch malfunction signal notification on display

Than connect VTT and checked fault code, found 1 fault code  inactive , relevant to clutch system.
1- TECU- P107538- Clutch system, Signal frequency incorrect.

As per DTC checked service bulletin and S/W update found this DTC also describe operation no- 41382-3- Clutch system DTC P107538, extended troubleshooting instructions.

According to operation no(40083-3) checked Clutch valve leak test and clutch performance test found both has got green tick
And checked clutch cylinder test , also get green tick during performed task.

That time noticed air continue leakage from gearbox bottom side .
 .

As per known DTC gearbox removed and physically checked clutch plate found its torsional spring got excess play while pressure plate found ok but

phycasaly check clutch cylinder and press through hand ,  found doesnt susten air pressure .

Than dismental clutch cylinder that time notice its internal seal damage

suspected ;- Too much dust enter inclutch cylinderand  internal seal got damage .

Note- so need to replace clutch cylinder only.
Fault codes registered in vehicle (Including Active and Inactive Faults)

Fault codes registered in vehicle (Including Active and Inactive Faults)

Is the causal part a recently modified one

If Yes, kindly provide more details about the modification:

Is this a repeat failure		Is yes, provide relavant details

Relavant Argus No. If any		Relavant DQR No. If any		Relavant MQR No. If any

Relavant QJ No. If any

Affected Vehicle details

Chassis No	Model	Body No	Date of Delivery	Date of Failure	Mileage Kms	Engine hrs	Parts Sl.no

Area(Photos Where required/Applicable)

Photo Area(JPG file only, Max. Size:500 KB)	Description/Remarks
Remove File	1- Door no- V-68
Remove File	2- HMR- 5308 KMR- 72680
Remove File	2- Physiclly checked not found external damage
Remove File	3- Causal part no- 24602826 Seria;l no- 241630695

Probable Cause of Failure

Corrective Action/Suggestions

Service and Repair History of the vehicle (Relevant to the failure)

S.No.	Job Card No.	Date	Mileage Kms	Engine Hrs.	Job carried out	Remarks

Repair Estimate

Material Cost

S.No.	Part no	Description	Qty	Unit Price	Net Price	GST %	GST. Amt	Net Price including GST	Pay code	Remarks



Total Net Price								92596.00

Labour cost

S.No.	Operation No	Description	Qty	Unit Price	Net Price	GST %	GST. Amt	Net Price including GST	Pay code	Remarks





Total Net Price								4338.27

Other cost

S.No.	Description	Qty	Unit Price	Net Price	GST %	GST. Amt	Net Price including GST	Pay code	Remarks

Total Net Price							0.00

Total cost of Repair( Material, Labor and Other cost)

Any Local solution or suggestion from the Field team for Prevention/ Quick resolution of Complaint

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test	1754475439_GD_REPORT.pdf Remove File	Compulsory for all failures having fault codes
17034-3 Vehicle information test	1754475440_TEST_REPORT.pdf Remove File	Compulsory for all failures having fault codes
28486-3 Sensor Values History Report		Compulsory for all failures related with the engine
20007-3: Engine protection data
28407-3 Sensor Values, Monitoring
20005-3: Fuel consumption data
28108-8 Engine ECU, check		Compulsary for all failures related with the engine ECU
PDF file of the Repair history of the vehicle in LDS– complete		Optional
Scan or Fax copy of the Last BS or AS (as applicable) checksheet		Compulsary
Completely filled checksheets and Protocols as given in Impact/FAG in YVD for the complaint		Compulsary

Additional Attachments

S.No.	Attatchemnt
1	Attachement File Remove File (PDF/Word/Excel file only, Max. Size:1024 KB)
2	(PDF/Word/Excel file only, Max. Size:1024 KB)
3	(PDF/Word/Excel file only, Max. Size:1024 KB)
4	(PDF/Word/Excel file only, Max. Size:1024 KB)
5	(PDF/Word/Excel file only, Max. Size:1024 KB)
6	(PDF/Word/Excel file only, Max. Size:1024 KB)

Oil & Fuel Sample Test Reports (Compulsory for all major engine related failures):

Sample Date		Sent to ELF Mumbai

Dispatch Details of Failed Parts( Mandatory for critical failures/failures related to safety/failures related to performance)

Docket No		Dispatch Date		Courier Name		Transporter Veh No.

Present Status of the vehicle

Present Status		Reason

Comments

S.No.	Remarks	By	Date & Time	TFAR Status
1	Dear Sourav, Now clutch cylinder got failure under vehicle warranty. Regards, Pappu	pkumar11	2025-08-06 17:32:33	TFAR RAISED
2	pls mention 3C in comment while raising TFAR	jjadav	2025-08-06 18:18:25	QUERY RAISED
3	C1- Gear not shifting and air leakage flywheel side and also PTO not posible to engage . C2- After test clutch cylinder and PWM valve got green tick but visually checked clutch found internal seal got damage . C3- Need to replace clutch cylinder	pkumar11	2025-08-07 09:48:45	TFAR RAISED
4	To correct	jjadav	2025-08-09 10:10:09	QUERY RAISED
5	done	jjadav	2025-08-09 10:11:06	REPLY TO QUERY
6	Dear Sir, Vehicle reported for the first time with clutch cylinder failure case at 5308EH. The failure has met the faulty clutch cylinder warranty parameters as mentioned in latest TII with DTC P107538 was set for 30 times in this vehicles. Hence, request you to kindly approve this case to close under Vehicle warranty.	jjadav	2025-08-09 10:14:46	TFAR FORWARDED
7	OK, Recommended and forwarded for further processing.	arai	2025-08-09 00:35:39	TFAR FORWARDED
8	OK, Recommended and forwarded for further processing.	arai	2025-08-09 00:44:22	TFAR FORWARDED
9	EHRS 5308, OK to replace uw	arai	2025-08-09 00:51:54	APPROVED

Query/Reply		TFAR Status