Part 2
Part 2 of 5WARNING: Before using an air line ensure all necessary safety precautions are taken to prevent personal injury, i.e., safety glasses, protective clothing etc.
Fit Inhibitor Switch
1. Fit new inhibitor switch if existing one was damaged.
2. Replace retaining plate and fix with spring washer and bolt, securing tightly.
4th Gear Assembly Overhaul
1. Using soft-jawed vice secure the 4th gear assembly by gripping the output shaft.
2. Remove the sungear.
3. Remove the planet gear assembly.
NOTE: Removal of snap-ring on assembly is not necessary unless damage has occurred.
4. Remove the disc washer, axial bearing and thrust washer.
5. Remove assembly from the vice and turn upside down onto the bench.
6. Remove cylinder F from cylinder E.
7. Remove cylinder E from the freewheel 3rd.
8. Remove axial disc, cage and two thrust washers.
9. Using pliers and screwdriver remove the snap-ring on carrier E.
10. Turn the assembly around and remove the output shaft from ring gear by pushing the gear downwards.
NOTE: Do not remove the snap-ring on output shaft.
11. Place ring gear on bench, teeth side down.
12. Remove carrier F from the ring gear assembly.
13. Remove the freewheel cage assembly from the ring gear by using an upward turning motion.
14. Remove the snap-ring retaining the freewheel ring (inner) to the hollow gear.
15. Remove the freewheel ring (inner) from the hollow gear.
16. Remove freewheel cage from freewheel ring (outer).
NOTE: Care should be taken when removing the freewheel ring, which due to the rollers and springs becoming loose may fall out.
17. Remove the snap-ring retaining the clutch plates and steel plates in cylinder F.
18. Remove four clutch plates and five steel plates from cylinder F.
19. Using clutch spring compressor LST1016-1, press down on the spring plate and remove the split rings.
20. Remove the spring plate.
21. Turn the cylinder upside down, using two small punches placed in the holes (diametrically opposite each other), push down and remove the piston.
22. Remove and discard the two O-rings from the piston.
NOTE: The five sealing rings do not need to be removed on the cylinder unless any damage has occurred to them.
23. Remove the snap ring from cylinder E.
24. Remove the four clutch plates and five steel plates from cylinder E.
25. Using clutch spring compressor LST1016-1, press down on the spring plate and remove the split rings.
26. Remove the pressure plate.
27. Remove piston E by using air pressure directed into the oil feed hole.
28. Remove and discard the two O-rings from the piston.
NOTE: Do not remove the snap-ring at the bottom of the E cylinder, unless damaged.
Assemble
29. Fit three seal rings on the outside hub and two seal rings on inside hub of cylinder F if they have been removed.
NOTE: Ensure each seal ring is snapped together.
30. Fit new O-rings onto the F piston.
NOTE: For ease of assembly apply Petroleum jelly on O-rings and stretch the inner O-ring to avoid damage on installation.
31. Fit piston F into cylinder F.
32. Fit spring plate using clutch spring compressor LST116-1.
33. Fit the two halves of the split ring to secure the spring plate in position, then remove the clutch spring compressor.
34. Install the clutch plates and steel plates into the F cylinder starting with a steel plate then clutch plate finishing up with the end plate which is thicker than the normal steel plates.
35. Fit the snap-ring into cylinder F to retain the clutch plate assembly.
NOTE: Do not confuse the steel plates of F clutch with that of the E clutch. The differences are thus: F clutch-steel plates are thicker and the end plate has no inner teeth.
36. Fit new snap-ring at bottom of cylinder E if it has been removed.
37. Fit the two O-rings onto the E piston.
NOTE: For ease of assembly apply Petroleum jelly.
38. Fit E piston into cylinder E.
39. Fit the pressure plate with depression facing downwards.
40. Fit spring plate using clutch spring compressor LST1016-1.
41. Fit the two halves of the split ring to secure the spring plate in position then remove the clutch spring compressor.
42. Install the clutch plates and steel plates, starting with a steel plate then clutch plate, finishing up with the end plate which is thicker than the normal steel plates.
43. Fit the snap-ring into cylinder E to retain the clutch plate assembly.
NOTE: Do not confuse the steel plates of E clutch with that of the F clutch. The differences are thus: E clutch-steel plates are thinner and the end plate has inner teeth.
44. Fit the freewheel ring (inner) to the hollow gear.
45. Secure using the snap-ring.
46. Fit freewheel cage into the freewheel ring (outer), and press home.
47. Turn the freewheel cage in the freewheel ring (outer) until rim of the cage has been seated.
48. Fit carrier E to freewheel cage assembly.
49. Fit freewheel cage assembly to ring gear assembly using a clockwise motion.
50. A minimum clearance of 0.1 mm (0.0039 in) should be obtained between the freewheel cage assembly and ring gear.
51. Inspect the output shaft for damage to the snap-ring, if any, replace snap-ring; also remove O-ring and discard, replace with new O-ring.
52. Align inner teeth of carrier E with freewheel ring (inner) teeth and then place freewheel 3rd assembly onto the output shaft.
53. Secure snap-ring into position, retaining the freewheel 3rd.
54. Fit the steel thrust washer and then the copper thrust washer onto the freewheel 3rd assembly.
55. Fit cylinder E onto freewheel 3rd assembly using a turning motion, ensuring that the teeth of the end plate line up with the freewheel ring (outer).
NOTE: When correctly assembled, copper thrust washer must be touching cylinder E assembly. The cylinder E assembly will turn in a clockwise direction when holding the output shaft. If the cylinder E assembly is turned in a counter clockwise direction the freewheel will lock up.
56. Fit the axial cage and axial disc onto the rear of cylinder E.
57. Using a turning motion, fit cylinder F assembly onto cylinder E assembly.
58. When correctly mounted the raised edge of the output shaft will be 10.00 mm (0.393 in) above the top surface of cylinder F assembly.
NOTE: Disengagement of end plate and freewheel ring (inner) will occur if end play exceeds 3.00 mm (0.118 in).
59. Fit the complete 4th gear assembly into the transmission, ensuring that the oil feed holes in cylinder F line up with the corresponding holes in the transmission casing.
60. Secure the 4th gear assembly to the transmission using ten countersunk screws. Tighten screws to 22-28 Nm (16-21 ft lbs).
NOTE: If screws are not tightened correctly, clutch pressure will be lost in clutch F.
61. Turn the transmission so that the front of the case is uppermost.
62. Fit the disc washer, axial cage and thrust washer onto the 4th gear assembly.
63. Fit the seal ring onto the planetary case and snap together if ring has been removed.
64. Fit the planetary set into the hollow gear using a turning motion.
65. Fit the sun gear onto the planetary set.