Part 4
Part 4 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.
Clutch B Overhaul
1. Place B clutch assembly with open face upwards.
2. Remove the snap-ring from inside the assembly.
3. Remove the four clutch plates and five steel plates.
4. Using clutch spring compressor LST1016-1, depress spring plate and remove snap-ring and retaining washer.
5. Remove the spring plate.
6. For ease of removal of the piston B, use air pressure fed through the oil feed hole, then turn assembly upside down and tap lightly on the working surface.
7. Remove and discard the two O-rings on piston B.
8. Remove seal ring on bottom of B cylinder if damage has occurred.
Assemble
9. Fit the two O-rings onto piston B.
NOTE: For ease of assembly use a Petroleum Jelly.
10. Install piston B into cylinder B.
11. Place spring plate into cylinder B and using clutch spring compressor LST1016-1, fit retaining washer (lips facing upward) and snap-ring.
12. Fit the clutch and steel plates starting with a steel plate finishing with the steel plate with three sets of three teeth grouped together.
13. Fit snap-ring into the clutch B assembly.
14. Turn upside down and fit seal ring and snap together if removed.
15. Install B clutch assembly into the transmission case, clutch plates facing upwards.
16. Using B clutch O-ring and snap-ring replacer LST116, fit O-ring, support ring and finally the snap-ring.
A Clutch Assembly Overhaul
1. Remove the input shaft by holding the A clutch assembly firmly and pushing the shaft against the working surface. Remove the O-ring and discard.
2. Using a suitable press, depress the A-B carrier and remove the snap-ring.
3. Remove carrier A-B.
4. Remove the six clutch plates and seven steel plates, plus two wavy spring plates fitted to later transmissions.
NOTE: If there is evidence of clutch slip or if the plates are worn, replace the clutch unit using the latest type.
5. Remove spring plate.
6. For ease of removal of piston A use air pressure fed through the oil feed hole.
7. Remove and discard both O-rings on piston A.
Assemble
8. Fit the two O-rings onto piston A.
9. Place the piston into cylinder A.
10. Fit the spring plate into the cylinder A with the convex side facing the piston.
11. Placing carrier A-B on the bench, fit the clutch unit. If the latest clutch unit is being fitted, see illustration for the correct build sequence. Note also that one steel plate is of alternative thickness.
12. Fit carrier A-B with the clutch assembly onto cylinder A.
13. Using a suitable press, depress the A-B carrier and secure with the snap-ring.
14. Fit the two seal rings, if removed, and an O-ring onto the input shaft.
15. Fit the input shaft into the cylinder A assembly and press downwards until shaft meets the stop.
16. Fit the thrust washer onto the input shaft seat.
NOTE: Use Petroleum Jelly to retain washer in place.
17. Install the inner carrier A onto the intermediate shaft within the transmission.
18. Place the disc washer and axial cage into the inner carrier A.
19. Fit cylinder A assembly into the transmission using a right to left twisting motion. This will enable the teeth of the clutch plates to mesh into the A-B carrier and inner carrier.
NOTE: When properly engaged the top of the cylinder A should not protrude more than 8.5 mm (0.33 in) above the transmission front face.
20. Place the thrust washer and axial cage onto the A cylinder.
Pump, Intermediate Plate and Bell Housing - Remove and Overhaul
1. Place the bell housing on the bench, open face down.
2. Remove the eight hexagonal bolts on the rear of the pump.
3. Screw in two bolts, diagonally opposite each other, tap lightly using a soft-headed mallet, this will free the pump assembly from the intermediate plate.
4. Remove the six remaining bolts situated on the inside of the bell housing.
5. Separate the bell housing from the intermediate plate.
Pump Assembly
6. Using a suitable tool remove the shaft sealing ring and O-ring from the pump housing and discard.
7. Strip, inspect and clean the pump assembly using a lint-free rag.
NOTE: If damage has occurred to the assembly, replace the whole pump.
8. Replace the pump hollow gear and pump gear into pump housing with the marked side of gears facing upwards.
9. Fit the O-ring onto the circumference of the pump housing.
10. Using oil seal replacer LST108, fit the shaft seal ring into the pump housing.
11. Fit the alignment pin into the pump housing.
Intermediate Assembly
12. Remove the four screw plugs and seal rings from the plate and discard the seal ring.
13. Remove the oil cooler pipe adaptors.
14. Inspect and clean the intermediate plate with a lint-free rag.
NOTE: If damage is found replace the intermediate plate.
15. Fit the oil cooler pipe adaptors.
16. Fit the four screw plugs into their correct locations with new seal rings.
Refit Bell Housing, Intermediate Plate And Pump Assembly
17. Inspect and clean the bell housing.
NOTE: If damage is found replace the bell housing
18. Align the dowel in the pump with its hole in the intermediate plate and press the housing into position.
19. Secure the pump housing to the intermediate plate with the eight hexagonal bolts and tighten to 46 Nm (34 ft lbs).
20. Using the oil pump rotation sleeve LST111 check that the pump gears rotate freely.
21. Place the gasket and disc washer onto the intermediate plate assembly using a petroleum jelly.
22. Fit the intermediate plate onto the transmission.
23. Fit the bell housing onto the intermediate plate assembly.
24. Secure with the six short bolts which locate on the outside diameter ring pattern within the bell housing and the twelve long bolts which are located in the inner diameter ring pattern. Tighten all the bolts to 46 Nm (34 ft lbs).
25. Using the end-float gauge LST111 check the axial clearance 0.2 to 0.4 mm (0.008 to 0.016 in). If the axial clearance is not achieved, remove the bell housing/intermediate plate assembly complete and replace existing disc washer using a thicker or thinner one depending on the reading first taken. Re-assemble bell housing/intermediate plate and check the axial clearance once again. Repeat this operation until axial clearance has been achieved.