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Section F
127 - 8
Assembly (cont'd)
Fit the 4WD Clutch Assembly
6
a
Fit the 4WD clutch oil feed pipe 6a at the casing.
b
Make sure the shaft bearing outer cup is correctly
located in the front casing (not shown) and then locate
the clutch and shaft assembly 6b in the the housing.
*
c
Make sure that the front and 4WD casing (6c) mating
faces are clean and undamaged. Apply a 3 mm bead of
Loctite 509 to the front casing as shown at A. Note that
the bead is applied near the inner or outer edge of the
flange as applicable at positions Y. Make sure that the
shaft bearing outer cup (not shown) is correctly located
inside the 4WD casing and then fit the casing. Fit 8 off
bolts 6e and progressively torque tighten to 56 Nm
Check the 4WD clutch shaft end float:
Provided components are assembled correctly the end float
will be within the limits given. Rotate the shaft by hand, it
should rotate smoothly.
The end float can be checked to confirm correct assembly.
End float must be within the range 0.01 mm to 0.16 mm
(0.0004 to 0.0063 in).
d
Fit a bolt to the threaded hole in the end of the shaft. Pull
up on the bolt to detect excessive end float.
e
Fit a new oil seal 6f. Make sure the seal is pushed
square to the housing.
f
Fit the output yoke 6g, followed by thick washer 6h and
bolt 6j. Hold the yoke using service tool 892/00812 and
at the same time torque tigten the bolt to 400 Nm (295
lbf ft).
7
Fit the Torque Converter Relief Valve
*
Note: The torque converter relief valve may be of a ball type
(shown at B), or poppet type (shown at C).
a
Fit the ball or poppet (see note above) 7a followed by
the spring 7b. Using a new sealing washer fit plug 7c.
8
Fit the Pressure Maintenance Valve
a
Oil the spool 8a and fit to the casing. Fit spring 8b. Apply
JCB Threadlocker and Sealer to the plug 8c. Using a
new sealing washer fit plug.
9
Fit the Gearbox Hydraulic Pump
a
Make sure that the pump is fitted with a new oil seal 9a,
see Powershift Gearbox, Inspection, step 4.
Fit a new sealing ring 9b. Locate the pump over the
input shaft aligning the bolt holes. Apply JCB
Threadlocker and Sealer to bolts 9c. Fit the bolts
together with new sealing washers 9d. Progressively
torque tighten the bolts to 28 Nm (20 lbf ft).
b
Pour some clean, new, oil into the pump at position X.
9803/3280
Transmission
Powershift Gearbox
Purchased from www.WorkshopManuals.co.uk
Section F
127 - 8
Issue 3*
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