TFAR

VOLVO TRUCKS (VECV) - Technical Failure Analysis Report

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

Subject/Complaint
Gear shifting problem.
Report Number	692100-2025-70427	Report Date	02-Aug-2025	Prepared By	vkchaubey1
Dealer ID	692100	Dealer Name	VSPC-Jaipur
Customer Name	South West Mining Limited / TI	Customer Contact Person	Mr. Naveen Sethia
Workshop/Site-Location	Barmer	Customer Contact Number	9772205254
Chassis Model with Axle Configuration	FM(4)-B 460 8X4 BS6	Body CuM & Application	20.3 cum RB HYVA
Chassis No	8-988649	Reg. Number	Door No 58	Date of Delivery	04-Jun-2024
Date of failure	02-Aug-2025	Repair Order No.	813	Repair Date	02-Aug-2025
Failure Mileage kms	100643	Age in Months	15	Engine Hrs.	8515
Function Group	4134	Causal Part No.	23867775	Description	Clutch Cylinder
Defect Code Group	2 LEAKAGE/ CONSUMPTION	Defect Code	21-GAS,AIR
Spare parts warranty	No	Spare parts invoice details		Spare parts fitment date	0000-00-00
Driveline Warranty	Yes	GDR No

Repair Estimate Summary

Material Cost	97021.79	Labor Cost	3833.82	Other Cost

Road Details

Type of road surface (Asphalt, Soil Gravel, Sharp stones etc.	SOIL
Dust Condition (Heavy Slight, etc.,)	SLIGHT
Approx. Gradient of the Road (required for engine and wheel Hub failures	1:16
Undulation on the Road( Heavy,Slight, Lot of pot holes, large Bumps, etc.)	SLIGHT
Was the vehicle travelling Uphill or Downhill (required for engine and wheel hud failures	NA

Load Details

Type of load carried	OVER BURDEN	Permitted Technical GCW	49	GCW during failure	NA

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:

Gear shifting problem.

Technical Explination of complaint (Dealer comment):

The vehicle came to the workshop with a complaint of a gear-shifting problem, checked and found:-

> We checked and found the gear not shifting: clutch malfunction showing in IC.
> Then we select the gear by the gear lever, but the vehicle does not move forward or reverse.
> Further, we checked the air pressure in the gauge and found the air pressure dropping during gear selection.
> But air is not leaking when the gear is in the neutral position.
> Then we connect VTT and find Active DTC P107538 Clutch system, signal frequency incorrect.
> Based on the DTC, we have performed the Clutch Engagement and Disengagement test found it failed.
> Then we have performed the PWM Valve test and found that the test has completed, but the value was above the expected value.
> After that, we checked air leakage from the gearbox externally, but we did not find air leakage
> Remove the gearbox and check the clutch cylinder, and found air leakage inside the clutch cylinder.
> The clutch plate and pressure plate are found in good condition.

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

Active DTCs in TECU: P107538 29 times.

Is the causal part a recently modified one	Yes

If Yes, kindly provide more details about the modification:

CPN 23867775 Superseded to 24602826

Is this a repeat failure	No	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	Description/Remarks
	Door No 48
	Chassis ID.: 8-988649
	K.M.-100643 H.M.R.-8515
	Fail part no.: 23867775 Serial no.: 234640557
	New part no. 24602826 Serial no. 251330083
	Fail part cylinder picture.
	New part to be fitted in vehicle picture.
	Fault code P107538 active 29 times in TECU.

Probable Cause of Failure

Suspected that there is an internal seal kit failure in the clutch cylinder, which creates air leakage from the clutch housing due to this clutch malfunction and gear shifting problem

Corrective Action/Suggestions

We need to replace the clutch cylinder and the consequential parts.

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
1	24604882	Clutch Cylinder	1	81966.27	81,966.27	5	4,098.31	86,064.58	09
2	24149906	Sealing Kit	1	6220.4	6,220.40	5	311.02	6,531.42	09
3	995906	Hexagon Screw; black	8	405.1	3,240.80	5	162.04	3,402.84	09
4	984050	Hexagon Nut	8	121.78	974.24	5	48.71	1,022.95	09
Total					92,401.71	Total		97,021.80

Labour cost

S.No.	Operation No	Description	Qty	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code
1	17012-3	Fault codes, reading	0.2	855	171.00	18	30.78	201.78	09
2	43170-1	Gear box, remove	1.2	855	1,026.00	18	184.68	1,210.68	09
3	41365-4	Clutch cylinder, replace	0.4	855	342.00	18	61.56	403.56	09
4	43172-1	Gear box, install	2	855	1,710.00	18	307.80	2,017.80	09
Total					3,249.00	Total		3,833.82

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)	100,855.62

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	1754141823_v-58_cc_gd.docx	Compulsory for all failures having fault codes
17034-3 Vehicle information test		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
--	--

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	Rectified & Running	Reason	Part was replaced.

Comments

S.No.	Remarks	By	Date & Time	TFAR Status
1	Dear sir 3C is following:- C1:-Gear shifting problem, clutch malfunction message sow in ic. C2:-Suspected that there is an internal seal kit failure in the clutch cylinder, which creates air leakage from the clutch housing due to this clutch malfunction and gear shifting problem. C3:-We need to replace the clutch cylinder and the consequential parts	vkchaubey1	2025-08-02 19:07:53	TFAR RAISED
2	For correction	vkchaubey1	2025-08-04 14:23:51	QUERY RAISED
3	Correction made	vkchaubey1	2025-08-04 14:37:53	REPLY TO QUERY
4	Dear Sir, As per SII 43-321-01 TRAG-G I-shift gearbox, Clutch cylinder failure, the fault code P107538 has appeared 29 times in the last 7 months. Hence requesting your approval for closing this case.	vkchaubey1	2025-08-04 14:39:39	TFAR FORWARDED
5	Dear Sir, Clutch failure reported at SWML Site. Being a known product failure, requesting your approval for closing this case.	ddubey2	2025-08-05 15:43:21	TFAR FORWARDED
6	OK for Warranty	ssdas	2025-08-08 00:19:50	APPROVED