133- 4
Section F
9803/3280
Section F
133 - 4
Issue 2*
Powershift Gearbox
Visually inspect the friction and counter plates:
Counter plates - light scoring/polishing is permissible,
plates that are not flat, worn or heavily marked or scored
must be replaced with a new set.
Friction plates - the cross hatching should be clearly
visible, plates that are not flat, have friction material
damage or scoring must be replaced with a new set.
DO NOT mix old and new plates, if a plate is damaged/worn
fit a complete new set.
Needle roller bearings should slide into position freely, do not
bend or distort the cage to fit. If the cage has been distorted
fit new bearings.
Take care when handling disc spring assemblies
18
to avoid
marking or damage, which could result in stress cracking. If
in doubt fit a new disc spring.
Note:
The piston incorporates a small check valve. Visually
inspect the piston to ensure the ball is in place and that the
seat is free from contamination. If necessary clean the valve
by blowing through with an air line. DO NOT use a wire rod
(or screwdriver) as damage to the valve seat could occur.
1
Fit new 'O' rings
25
and
24
. Lubricate the piston
23
with
oil and press fully into bore of clutch housing.
2
Fit oil baffle
22
, piston spring
21
, make sure the spring
seats in the piston.
3
Fit the spring retaining plate
20
.
4
Compress the spring and secure with circlip
19
.
5
Fit the disc spring assembly
18
. Make sure that the disc
spring is fitted with the teeth towards the clutch pack.
Make sure the teeth are not aligned with the lubrication
slots in the housing.
6
Fit one counter plate
17
followed by one friction plate
16
. Continue fitting alternate counter and friction plates,
finishing with a friction plate.
7
Fit the pressure end plate
14
, do not fit shim
15
at this
stage. Make sure that the chamfered face is fitted
facing the clutch pack as shown at
A
. Make sure the
teeth are not aligned with the lubrication slots in the
housing.
8
Fit the clutch friction/counter plates retaining circlip
13
.
PS760 - 6 Speed Clutch - Assembly
9
Using a dial test indicator as shown, measure the end
float of the pressure end plate
14
, which should be 1.9
to 2.5 mm (0.075 to 0.098 in).
If it is necessary to adjust the end float to bring it within
tolerance, there is a choice of fitting a 6.0mm (0.23in) or
6.5mm (0.25in) thick pressure end plate
14
, with either
a shim
15
or an extra counter plate
17
between the
retaining circlip
13
and pressure end plate
14
.Use an
airline to check the operation of the clutch.
10
Fit the thick thrust washer
12
, thrust bearing
11
and thin
thrust washer
10
.
11
Fit the needle roller bearing
9
.
12
Carefully align the teeth of the clutch plates using a thin
rod (or screwdriver) and fit the gear and splined hub
5
.
13
Fit the thin thrust washer
8
, thrust bearing
7
and thick
thrust washer
6
.
14
Smear the clutch end bearing
4
with gearbox oil and
press the bearing onto the shaft.
15
At the opposite end, press the gear
3
onto the shaft
spline. Make sure that the gear is fitted the correct way
round.
16
Smear the clutch end bearing
2
with gearbox oil and
press the bearing onto the shaft.
17
Fit piston ring seals
1
at each end of the shaft, refer to
Piston Ring Seals - Fitting Procedure
.
217590
*