Part 3
Part 3 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.
Refit Park Mechanism
1. Turn transmission into a horizontal position.
2. Fit leg spring over pin and place into rear of transmission.
3. Fit paw onto pin, to tension spring fit leg of spring into hole of pawl.
4. Fit plate and guide plate and tighten to 8 Nm (6 ft lbs) using Torx bit TX27.
5. Turn transmission so that the front of the case is uppermost.
6. Fit the disc and axial cage.
Brakes C, C1 and D with Planetary Sets - Overhaul
1. Remove the center plate assembly.
2. Remove the two brake C1 clutches and two steel plates from cylinder C-D.
3. Remove freewheel 2nd complete.
4. Remove the two brake C1 clutches and three steel plates from cylinder C-D.
5. Remove the cylinder C-D with brake D assembly.
6. Remove the support ring from the planetary sets assembly.
7. Remove the front planetary set with freewheel assembly.
8. Remove the sunshaft from the assembly.
NOTE: Do not remove the seal ring from the sunshaft unless damaged.
9. Remove the snap-ring from the hollow gear.
10. Remove the hollow gear from the assembly.
11. Remove the rear planetary set.
12. Remove the thrust washer and axial bearing.
13. Remove the intermediate shaft with the hollow gear complete.
14. Remove the axial bearing and two thrust washers, one from each side of the bearing.
15. Remove the distance ring.
NOTE: The snap-ring in the webshaft need only be removed if damaged.
16. Holding the hollow gear with the rear face uppermost, remove the snap-ring.
17. Disconnect the hollow gear from the intermediate shaft.
18. Remove the external snap-ring from the brake D assembly.
19. Remove the four clutch plates and five steel plates from the assembly.
20. Using clutch spring compressor LST1016-1 press down on the spring plate to remove the split rings.
21. Turn cylinder C-D upside down and using the clutch spring compressor, remove the snap-ring with pliers.
22. Remove the spring plate.
23. For ease of removal of both piston C and piston D, use air pressure fed through the oil feed holes.
24. Discard O-rings from both piston assemblies.
25. Using the clutch spring compressor remove the spring plate, as previously explained, from the center plate assembly.
26. To remove the piston use air pressure as previously described and discard O-rings.
Assemble
27. Secure the webshaft into a soft-jawed vice.
28. Fit the snap-ring if it has been removed into the lower groove.
29. Fit the distance ring into the webshaft.
30. Place a disc washer and axial cage into the assembly.
31. Assemble together the hollow gear with the intermediate shaft and secure with the snap-ring.
32. Place the other disc washer onto the rear of the intermediate shaft using grease.
33. Fit the intermediate shaft assembly into the webshaft ensuring the disc washer mates up to the axial cage.
34. Using a turning motion fit the rear planetary set into the hollow gear.
35. Fit the front hollow gear into the webshaft assembly and secure with a snap-ring.
36. Insert disc washer and axial cage.
37. Place support ring onto the webshaft assembly.
38. Tap the two fitting pegs down into the slots on the side of the cylinder C-D if they have been removed.
39. Place the two O-rings onto piston D.
NOTE: For ease of assembly, apply Petroleum jelly to the O-rings.
40. Fit the D piston into cylinder C-D ensuring that the correct side is selected, that is, the side with the least number of slots in cylinder C-D.
41. Fit the spring plate and using the clutch spring compressor LST1016-1, fit the snap-ring into the groove.
42. Place the two O-rings onto piston C.
NOTE: For ease of assembly, apply Petroleum Jelly to the O-rings.
43. Fit the C piston into cylinder C-D.
44. Using the clutch spring compressor LST1016-1, fit the spring plate and the two halves of the split rings.
45. With the clutch D opening uppermost, fit the planetary set with freewheel 1st gear onto the hub of cylinder C-D.
46. Fit the clutch plates and steel plates starting with a steel plate then a clutch plate, finishing up with the thin end plate.
47. Fit the snap-ring on the outside of the C-D cylinder which secures the D clutch assembly.
48. Fit two seal rings onto the sunshaft and snap together if they have been removed.
49. Fit the sunshaft into the planetary set, splines first.
50. Turning the whole assembly around so the C clutch side is uppermost, fit the assembly into the webshaft assembly.
51. Fit freewheel second onto the sunshaft, before fitting align the upper and lower halves.
NOTE: To ensure correct fitment of the freewheel second, the top of the assembly is marked with the word OPEN.
52. Fit the C clutch plates and steel plates starting with a steel plate then a clutch plate into the longer slots of C-D cylinder.
53. Fit end plate which has three groups of three teeth, of which the middle tooth must fit into the short slots in the C-D cylinder.
54. Fit the C1 clutch assembly starting with a clutch plate ending with a steel plate.
NOTE: When fitting these plates ensure teeth on the outside do not go into the V shaped area of the C-D cylinder. If thin steel plates have to be added into the C or C1 clutch assembly ensure that these plates are placed on the side nearer to the respective pistons.
55. Fit the two O-rings onto the piston C1.
NOTE: For ease of assembly, use Petroleum Jelly.
56. Fit C1 piston assembly into center plate.
57. Using clutch spring compressor LST1016-1, fit spring plate and the two halves of the split rings.
58. Place the center plate onto the C-D cylinder making sure that the V shape in the plate locates in the V shaped hollow in the C-D cylinder.
59. Remove the C, C1 and D clutch assembly from vice and place a greased thrust washer to the rear face of the webshaft.
60. Fit the whole assembly into the transmission case using the gear train remover/replacer LST117, ensuring that the oil feed holes are aligned with those in the bottom of the casing.
61. Secure the whole assembly with a snap-ring which fits into the groove inside the casing.