TFAR

VOLVO TRUCKS (VECV) - Technical Failure Analysis Report

Purpose of TFAR	Approval	Approval / feedback	Technical Goodwill	Type of TFAR	Truck Chassis

Subject/Complaint
During daily maintenance customer mechanic saying that Steering oil leakage from gearbox top cover
Report Number	693300-1-2024-53362	Report Date	05-Mar-2024	Prepared By	PST RGM
Dealer ID	693300-1	Dealer Name	VSPC- Kothagudem 1
Customer Name	S.V Engineering construction	Customer Contact Person	R.Venkateswaralu
Workshop/Site-Location	OCP-3	Customer Contact Number	9989179506
Chassis Model with Axle Configuration	FM(4)-B 500 8X4 BS4	Body CuM & Application	SAE 25.2 Cum Wider Rock Body
Chassis No	8-972372	Reg. Number		Date of Delivery	26-Apr-2022
Date of failure	05-Mar-2024	Repair Order No.		Repair Date
Failure Mileage kms	127996	Age in Months	23	Engine Hrs.	11515
Function Group	642	Causal Part No.	250415	Description	Steering gear
Defect Code Group	2 LEAKAGE/ CONSUMPTION	Defect Code	28-HYDRAULIC OIL
Spare parts warranty	No	Spare parts invoice details		Spare parts fitment date	0000-00-00
Driveline Warranty	No	GDR No

Repair Estimate Summary

Material Cost	605258.44	Labor Cost	1720.44	Other Cost	2456.99

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	59	GCW during failure	No

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	Basker	Training details on the related variant	Yes

Drivers description on the happening of the failure:

During daily maintenance customer mechanic saying that Steering oil leakage from gearbox top cover.

Technical Explination of complaint (Dealer comment):

1.As per complaint inspect the truck steering oil leakage from valve housing and steering gear top cover area.
2.Further we have checked the Hydraulic hose with connectors and adapters and found ok.
3.Then we have checked the top cover screw torque 190Nm as per spec.
4.then check the wheel end stopper screws found intact and steering linkages found good,
5.Oil leaking occurring from the top seal and earlier we observed this type of cases in same and other sites
6.Suspecting that leakage occurring from the shaft seal which is not supplying in our sealing kit
7.If we dismantle the gear box to replace the seal kit it will be not useful if leakage from shaft seal
8.And vehicle will be off road till gear box arrival and getting approvals
9.Oil entering into the VDS electric motor also, consequently it will damage the VDS electric motor. Similar case we observed in same site
10.By considering the above points we are requiring the steering gear box to replace.

Last seal kit repair details.

Tfar no:693300-1-2023-46884 KMR:85852 HMR:7602 DT:04-July-23 .

Note: CP Number and SL Number are available on the steering gear and the SL Number is of .500272

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

NO.

Is the causal part a recently modified one

If Yes, kindly provide more details about the modification:

NO.

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
	As per impact steering gear slno:500272
	Failure KMR/HMR
	Failure vehicle view
	Steering oil leak from steering gear top side.
	Steering gear casual part & slno:250415 & 500272
	Electric motor slno & casual part sticker missing.
	Steering oil enter to electric motor inner side view.
	As per vda+ electric motor casual part no is:23444205

Probable Cause of Failure

Suspecting oil entry consequently due to seal kit failure in gear box lead to failure of steering motor.

Corrective Action/Suggestions

Need to replace the suggested 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	24138148	Eletric motor	1	239853.83	239,853.83	28	67,159.07	307,012.90	9
2	250415	Steering gear	1	233004.33	233,004.33	28	65,241.21	298,245.54	9
Total					472,858.16	Total		605,258.44

Labour cost

S.No.	Operation No	Description	Qty	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code
1	64212-2	Steering electric motor, replace	1.3	810	1,053.00	18	189.54	1,242.54	9
2	17906-2	Diagnostic with Tech Tool/GD. Connect-disconnect of diagnostic tool included. Fault codes reading.	0.5	810	405.00	18	72.90	477.90	9
Total					1,458.00	Total		1,720.44

Other cost

S.No.	Description	Qty	Unit Price	Net Price	GST %	GST Amt.	Net Price including GST	Pay code	Remarks
1	Steering oil 1161995-1	9	213.28	1,919.52	28	537.47	2,456.99	9
Total				1,919.52	Total		2,456.99

Total cost of Repair( Material, Labor and Other cost)	609,435.87

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		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	Running with Problem	Reason	Waiting for approval

Comments

S.No.	Remarks	By	Date & Time	TFAR Status
1	Dear Nagaraju, Following 3C For your kind reference. C1- During daily maintenance technician observed that Steering oil leakage from gearbox top cover. C2- As per complaint inspect the truck steering oil leakage from valve housing and steering gear top cover area. As per our previous experience the steering oil leaked from these steering gear input shaft top side center portion and that STG Oil entered into the steering motor and the oil comes out through the connector in the FAS and the leakage is visible and it leads the FAS Failed. C3-Needs to be replace the STG Gear and FAS. Truck present status running with problem. Please check and support to Kindly forward the TFAR as per approval matrix for further approvals	PST RGM	2024-03-05 20:45:59	TFAR RAISED
2	HI Suhas, This is known failure, Please check and support to close the issue under cost sharing TGW	pnagaraju	2024-03-06 15:09:09	TFAR FORWARDED
3	Approved 50 percent under TGW	suhast	2024-05-13 10:54:40	APPROVED