PRM NEWAGE PRM125D, Workshop Manual

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14 - PRM125
9.6.2 Gearcase assembly
Remove the external Locknut (33) securing Idler Shaft (2) into Gearcase. Remove the ten Bolts (36) securing both
Gearcases (1, 29) and using a soft mallet lightly tap on the end of the Input Shaft (4) to separate the two Gearcase (1,
29) halves from sealant and Dowels (44). Remove the Front Cover (29) . Withdraw the Idler Shaft (2) the Output Shaft
assembly and the Input Shaft (4) .
9.6.3 Input Shaft
Using a bearing puller remove the two Bearings (25) ensuring the cups remain with their respective cones.
Removal of the Bearings (25) may result in damage them, therefore it is good practice to replace these items if
removed. (see 9.4.3)
9.6.4 Output Shaft
Carefully remove “staked” portion of locking device so as to avoid damaging the thread and remove Locknut (30) from
Output Shaft (19) . Using a bearing puller remove the Bearing (25) on the output end of the Output Shaft (19).
Remove the following: Thrust Washer (26) , Gear (3) , Needle Bearing (23) (carefully checking for wear), Thrust
Washer (22) and Cone Clutch (21) . Using puller remove the Bearing (25) cone on the Input end of the Shaft, Thrust
Washer (26), Output Reverse Gear (20) , Needle Bearing (23) (again carefully checking for wear), and Thrust Washer
(22) . Save Shims for rebuild.
Note: Removal of Taper Roller Bearings may result in damage, therefore it is good practice to replace these items if
removed. (see 9.4.3)
9.6.5 Idler shaft
Remove Locknut (33) again carefully removing the stacked portion to avoid damaging the thread and supporting Gear
(24) on soft material i.e. wood or similar to prevent damage to Gear (24), using a soft mallet tap the Idler Shaft (2)
through the Gear (24) and remove the Bearing (28) cone . Check condition of the
‘O’ Ring (49) on the Idler Shaft (2).
9.6.6 Selector
By hand remove Selector Shoe (9) and the Spring (8). Remove the Lever (13). Pass the Selector Control Body (7)
through the Selector Housing (5)
and remove ‘O’ Ring (12) and Oil Seal (6) if replacing them.
9.6.7 Front Cover
If it is required to replace the Front Cover (29) then it will be necessary to remove the Oil Seal (34) and Breather (37) .
If the Bearings (25) are to be re-used then care must be taken not to damage them on removal. The bearing cups can
be removed with the aid of two levers. It is recommended to fit a new Oil Seal (34).
Note: When re-fitting Oil Seal (34) set in 1.5mm from face as shown on page 18.
9.6.8 Gearcase
If it is required to replace the Gearcase (1) then again if the Bearings (25) are to be re-used care must be taken in their
removal. Remove Output Seal (31), Dipstick (39), Drain Plug (46), Filler Plug (46), Level Plug (47) and the two Dowels
(44) .
9.7 Re-assembly of gearbox
(Note: coat all bearings with clean gearbox oil prior to fitting).
9.7.1 Input Shaft
Press the two Bearings (25) onto the Input Shaft (4) taking care to position correctly as illustrated.
9.7.2 Output Shaft (see 9.7.5 for shimming procedure)
All of the following components are fitted over the Output Spline end of the Shaft.
Large bore Thrust Washer (26), Needle Bearing (23), Output Forward Gear (3) with Cone towards the scroll,
small bore Thrust Washer (22) and the Bearing Cone (25) (Press on).
Fit the following components from the opposite end of the Shaft (19) .
The Cone Clutch (21), large bore Thrust Washer (22), Needle Bearing (23), Output Reverse Gear (20) , small bore
Thrust Washer (26) press on Bearing cone (25) re-shim if components have been changed (see 9.7.5) fit Locknut (30) .
CAUTION:
Remember to tighten Locknuts to recommended torque.
(SEE TORQUE CHART 10.2)