PAGE 16
SERVICE INSTRUCTIONS
CONTINUED
340 REV.030926
6) Remove connecting shaft item 600, and internal gear item 430, from brake housing. Remove circlip item 431,
to separate internal gear from brake hub. Inspect needle bearing item 603. Replace if necessary.
7) Remove primary sungear item 440.
8) Pull primary planet hub assembly out of bushing item 774.
9) Remove thrust bearing item 617, and two thrust washers item 615, from primary planet hub item 400. Inspect
and replace if cracked or otherwise damaged.
10) Remove 16 capscrews item 111, and lockwashers item 113, to separate brake housing item 700, from final
housing item 100. Remove and discard O-ring item 107.
11) Remove eight capscrews item 771, and lockwashers item 773, one turn at a time, to relieve pressure being
exerted by brake springs item 752.
12) Inspect thrust washer item 776, and replace if less than 0.13 inch thick. Inspect bushing item 774, and replace
if inside bore is worn above 3.145 inch diameter.
13) Remove 18 brake springs item 752. Thoroughly examine springs for damage and measure overall length. Overall
spring length should be 2.27 inch. If any spring measures less than 2.21 inch replace all springs as a set.
14) Pull brake piston item 750, out of brake housing, using two 5/8 inch - 11 NC bolts screwed into two puller holes
in piston and discard O-rings item 751 and item 753.
15) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
DISASSEMBLY OF PRIMARY PLANET HUB ASSEMBLY:
Inspect three primary planet gears item 420, for damage or wear. If necessary, disassemble as follows:
1)
Remove circlips item 411, and press planet pins item 410, out of primary planet hub item 400. Remove planet
gears item 420, and inspect loose rollers item 423, and two thrust washers item 421. Replace if damaged.
2) Press sungear stopper item 444, out of primary planet hub and measure thickness. If less than 0.21 inch thick,
replace sungear stopper.
All parts have now been removed from brake housing and there is no need for further disassembly unless a failure
has been analysed in the remaining drive assembly.
DISASSEMBLY OF FINAL DRIVE AND OUTPUT SHAFT ASSEMBLY:
Refer to PARTS REFERENCE on page 22 and FINAL DRIVE GROUP drawing G1016 on page 23.
If final drive or output shaft assembly requires service or repair, disassemble as follows:
1) Remove final sungear item 340, from center of three final planet gears item 320.
2) Pull out final planet hub assembly and inspect for wear or damage. If final planet hub gears item 320, require
removal, take off circlip item 311, from planet pin item 310, and press planet pin out of final planet hub item 300.
Remove final planet gear item 320, and inspect thrust washers item 321, and loose rollers item 323. Replace
if damaged.
3) If Planematic drive includes an inboard or outboard flange, remove capscrew item 153, lockwasher item 155,
and flange cap item 154, to slide off flange item 152.
4) Remove six hex capscrews item 163, and lockwashers item 165. Pull off end cover item 156, and discard O-
ring item 167, and oil seal item 157.
5) Untab lockwasher item 161, from locknut item 159. Unscrew locknut and remove lockwasher and keyed washer
item 149. Output shaft item 150, can now be pressed out of tapered roller bearings items 151 and 103.
6) Check sungear stopper item 160, for wear and replace if less than 0.21 inch thick.
The Pullmaster Planematic drive has now been completely disassembled.
