DRESSTA TD-25M EXTRA, Service Manual

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SECTION 7C
TRANSMISSION
Page 26
TD-25M EXTRA DRESSTA
TRANSMISSION
55. Thoroughly oil friction discs (16) as described above. Alternately install one internally splined
friction disc (16) and one externally splined separator plate (17) in drum (26). There are fifteen
discs (16) and fourteen plates (17) used in this clutch pack.
56. Install clutch support plate (14) with retaining ring (15). Install retaining ring (9) and thrust
bearing (6) with thrust races (5).
57. Position reverse driver gear (8) over the end of the shaft (1). Be sure all the internally splined
discs (16) are aligned in drum (26) and that the gear meshes with all the discs.
58. Install bearing (7) in the bore of gear (8).
59. Reassemble thrust bearing (6) with thrust races (5).
60. Heat bearing cone (28) to 135 [°C] for 45 minutes and install on the shaft (1) until it bottoms.
To assure cone is seated, keep pressure against the cone until it cools down a few seconds.
61. If bearings (28) were replaced, press new bearing cup (28) in cover (4, Fig. 7C.7) and press
new bearing cup (28) in housing (1, Fig. 7C.7) with depth not less than 0.04 [mm].
Countershaft (Refer to Fig. 7C.16)
62. Install retaining rings (2) on shaft (1) if removed. Install gear (3) on shaft (1). Install retaining
ring (2).
63. Install gear (4) first, then install gear (5) on shaft (1). Install retaining ring (2).
NOTE: Gears (3,4 and 5) preheating up to to 120 [°C] max is allowed.
64. Heat bearing cones (11 and 13, Fig. 7C.7) to 135 [°C] for 45 minutes and install on the shaft
(1) until bottom. To assure cones are seated, keep pressure against the cones until they
cool down a few seconds.
65. If bearings (11 and 13, Fig. 7C.7) were replaced, press new bearing cup (11) in cover (4) and
press new bearing cup (13) in housing (1) with depth not less than 0.04 [mm].
Reverse Idler Shaft (Refer to Fig. 7C.15)
66. If bearings (3) or gear (2) were replaced, check that retaining ring (5) is properly seated in the
groove inside gear (2) and press one bearing cup (3) in the gear bore until it bottoms on
retaining ring (5). Turn the gear (2) over and press the second bearing cup (3) in the gear bore
until it bottoms on retaining ring (5).
67. If bearings (3) or shaft (1) was replaced, heat bearing cone (3) to 135 [°C] for 45 minutes and
install on shaft (1) until it bottoms. To assure cone is seated, keep pressure against the cone
until it cools a few seconds.
68. Install spacer (4) on the shaft (1) and insert the shaft through gear (2).
69. Heat second bearing cone (3) to 135 [°C] for 45 minutes and install on shaft (1) until it bottoms
against spacer (4). To assure cone is seated, keep pressure against the cone until it cools
a few seconds.
70. Insert the shaft assembly (1) into the transmission cover (4, Fig. 7C.7).
71. Install O-ring (8) and plate (6) on the outside of the transmission cover (4, Fig. 7C.7) and
secure with bolt (7). Torque the bolt to 325 [Nm].