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Section F
133- 4
PS760 - 6 Speed 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.
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.
9803/3280
Transmission
Powershift Gearbox
Purchased from www.WorkshopManuals.co.uk
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
Section F
133 - 4
Issue 2*
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