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Section F
131 - 6
PS760 - Layshaft Clutch - Assembly
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.
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 24 and 23. Lubricate the piston 22 with
oil and press fully into bore of clutch housing.
2
Fit oil baffle 21, piston spring 20, make sure the spring
seats in the piston.
3
Fit the spring retaining plate 19.
4
Compress the spring and secure with circlip 18.
5
Fit one counter plate 17 followed by one friction plate
16. Continue fitting alternate counter and friction plates,
finishing with a friction plate.
6
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.
Note: A spring disc is not fitted in this clutch pack.
7
Fit the clutch friction/counter plates retaining circlip 13.
8
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.
9803/3280
Transmission
Powershift Gearbox
Purchased from www.WorkshopManuals.co.uk
9
*
Fit the thick thrust washer 11, thin thrust washer 9A
thrust bearing 10 and thin thrust washer 9.
†
*
Thrust washer 9A not fitted to early clutch assemblies.
10
Fit the two needle roller bearings 8. The 4-speed
transmissions have only one needle roller bearing fitted.
11
Carefully align the teeth of the clutch plates using a thin
rod (or screwdriver) and fit the gear and splined hub 5.
12
Fit the thin thrust washers 6 and thrust bearing 7.
13
Fit the 4 wheel drive transfer gear 4 onto the layshaft
spline. Make sure that the gear is fitted the correct way
round. The 2 wheel drive machines have a spacer fitted
instead of a gear. Fit the circlip 3.
14
Smear the clutch end bearings 2 and 12 with gearbox
oil. Oil and press the bearings onto the shaft.
15
Fit piston ring seals 1, refer to Piston Ring Seals -
Fitting Procedure.
217590
Section F
131 - 6
†
,
Issue 1
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