VOLVO TRUCKS INDIA

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VOLVO TRUCKS (VECV) - Technical Failure Analysis Report


Purpose of TFAR
 Guidance
Approval / feedback
 Technical Feedback
Type of TFAR
 Bus Chassis
Subject/Complaint
As per customers complaint, check Engine system message pop-up in cluster
Report Number 69310-2025-71798 Report Date 16-Sep-2025 Prepared By bsambari
Dealer ID 69310 Dealer Name VSPC-Hyderabad
Customer Name GO TOUR TRAVELS AND HOLIDAYS Customer Contact Person
Workshop/Site-Location HYDERABAD Customer Contact Number
Chassis Model with Axle Configuration B8R(3) 9600s 6X2 - 15M - SLEEPER
Chassis No B8R-219699 Reg. Number MH12XN9594 Date of Delivery 05-Mar-2025
Date of failure 15-Sep-2025 Repair Order No. 13177 Repair Date 15-Sep-2025
Failure Mileage kms 153394 Age in Months 7
Function Group 25 Causal Part No. 24408677-VO Description EXHAUST BRAKE
Defect Code Group 1 NOISE/ VIBRATION Defect Code 13-WHISTLING NOISE
Spare parts warranty No Spare parts invoice details NA Spare parts fitment date
Spare Parts age in months 0 GDR No NA

Repair Estimate Summary

Material Cost 28503.19 Labor Cost 1715.13 Other Cost 0.00

Road Details

Route Hyderabad to Bengaluru Average running Kms per day 600
Type of Route Plain Highway Sharp curves Hilly Bad road
Percentage 70 % 10 % 10 % 10 %
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures) NA

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 NA Aggregate Part No. NA Aggregate Sr. No. NA

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

Driver Name SIVA Training details on the related variant Yes, Trained Driver
Drivers description on the happening of the failure: As per customers complaint, check Engine system message pop-up in cluster

Technical Explination of complaint (Dealer comment):

As per customers complaint, below observations noticed.

1) Check engine system pop-up message in cluster.
2) VTT connected and DTCs as below are in active status.
ECM - P0475 - 99, Exhaust Pressure Control Valve "A" - Exceeded Learning Limit
ECM - P0475 - 97, Exhaust Pressure Control Valve "A" - Component or System Operation Obstructed or Blocked
3) There is no fault tracing for above DTCs.
4) Then, checked the connector, wiring and connections found ok.
5) Noticed whistling noise from exhaust brake when connector is placed while vehicle is in Key ON position.
6) But when we removed the connector there is no noise observed vehicle is in Key ON position which has occurred due to exhaust brake was directed.
7) On further diagnosis, noticed that exhaust brake shut-off valve got stuck-up leads to whistling noise and low pick-up in the vehicle.
8) Replaced Exhaust brake under vehicle warranty.

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

ECM - P0475 - 99, Exhaust Pressure Control Valve "A" - Exceeded Learning Limit
ECM - P0475 - 97, Exhaust Pressure Control Valve "A" - Component or System Operation Obstructed or Blocked
Is this a repeat failure No Is yes, provide relavant details
Relavant Argus No. If any NA Relavant DQR No. If any NA Relavant MQR No. If any NA
Relavant QJ No. If any NA

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 Description/Remarks
Chassis ID: B8R-219699 Mileage: 153394KM
check Engine system message pop-up in cluster
Active fault codes
No fault tracing for this DTC ECM - P0475 - 99
No fault tracing for this DTC ECM - P0475 - 97
Exhaust pressure test found ok
Exhaust pressure test found ok
Casual part on the vehicle
Failure component
Connector found ok
Connector found ok
Measure voltage is 5V
Measure voltage is 2.3V
Measure voltage is 2.3V
Casual part no: 24408677-VO Casual part SL no: T243161027
Removed exhaust brake
Casual part - Exhaust brake
Casual part - Exhaust brake Shut off valve was stucked
Casual part - Exhaust brake
New exhaust brake shut off valve condition
Old part and New part
New part replaced
Exhaust brake replaced
New part no: 24408677-VO New part SL no: T242061047
As per VDA+ casual part details
Vehicle is under B01 Waranty

Probable Cause of Failure

Noticed that the exhaust brake shut-off valve got stuck, leading to a whistling noise and low pick-up in the vehicle.

Corrective Action/Suggestions

Replaced exhaust brake under vehicle warranty

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
1 IN8 24408677 EXHAUST BRAKE, E-ETV ASSEMBLY-124155.2524,155.25184,347.9528,503.2009
Total 24,155.25 Total 28,503.20

Labour cost

S.No. Operation No Description Qty. Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
1 25315-2 Exhaust brake, replace0.9855769.5018138.51908.0109
217906-2 Diagnostic with Tech Tool/GD 0.5855427.501876.95504.4509
3 25351-2 Response exhaust pressure0.3855256.501846.17302.6709
Total 1,453.50 Total 1,715.13

Other cost

S.No. Description Qty. Unit Price Net Price GST % GST Amt. Net Price including GST Pay code Remarks
Total 0.00 Total 0.00
Total cost of Repair( Material, Labor and Other cost) 30,218.33

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

NA

ANNEXURES (Select the annexure attached)

17012-3 VCADS Pro Error Codes Test Compulsory for all failures having fault codes
17034-3 Vehicle information test
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
Completely filled checksheets and Protocols as given in Impact/FAG in YVD for the complaint Optional

Additional Attachments

S.No. Attatchemnt
11758002507_Service_History_1_2025091611292363156.pdf
21758002809_PHV_2.0_Print_Page.pdf
31758003646_WhatsApp_Video_2025-09-15_at_14.09.48.mp4
41758003649_WhatsApp_Video_2025-09-15_at_14.09.36.mp4
51758004128_WhatsApp_Video_2025-09-15_at_11.16.08.mp4
6

Present Status of the vehicle

Present Status Rectified & Running Reason NA


Comments

S.No. Remarks By Date & Time TFAR Status
1Dear Sir,
Kindly forward the TFAR to TS team to secure approval under vehicle warranty.

Complaint: Check engine system pop-up message in cluster.
Cause: DTCs-P047599 and P047597-Exhaust pressure control valve - blocked/ Obstructed. There is no fault tracing for this DTCs. Performed exhaust pressure test found ok. No leakage and wiring found ok. Noticed whistling noise when we connected the connector and noticed that the exhaust brake shut-off valve got stuck, leading to a whistling noise and low pick-up in the vehicle.
Corrective action: Hence, replaced exhaust brake under vehicle warranty.		bsambari2025-09-16 12:33:48TFAR RAISED
2Hi,
Kindly guide us in proceeding with the claim as the part has been replaced due issue of low pick up and engine out put reported in the vehicle.
Regards
Mahendran		ksmahendran2025-09-16 13:51:48TFAR FORWARDED
3Hi,
YOu can proceed to seek support in this case as per the warranty protocols.		bashukur2025-09-17 12:44:22RETURNED
4Dear Bhavana,
Approved to claim the cost of the part and applicable labor charges under the scope of vehicle warranty since being justified that the exhaust throttle valve is internally faulty.
Regards
Mahendran		ksmahendran2025-09-17 13:15:40APPROVED
 
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