63 - 4
Power Take Off Clutch
Dismantling and Assembly
Idler Assembly
The idler assembly (items 33 - 37) can be dismantled after
the PTO clutch has been removed and must be assembled
before the PTO is replaced. Withdraw shaft 33 using an
impulse extractor screwed into the M12 tapped hole in the
end of the shaft, then remove the remaining components via
the PTO cavity. Assembly is the reverse of the dismantling
sequence.
Dismantling
Follow the numerical sequence on the illustration to
dismantle the unit, noting the points listed below.
Use suitable screws, inserted into the threaded holes
provided, to remove the brake piston 10.
Dowels 9 (3 off) should be removed if they are loose, to
prevent losing them.
Bearing 18 will either remain on the clutch shaft or in its
housing in the gearbox when the clutch is removed.
Dismantling of the clutch assembly 7 will be easier if it is
secured in a soft-jawed vice, coupling end lowermost.
Thrust washer 28 and ring 27 should be removed using a
bearing puller applied to thrust washer 28. Discard ring 27.
Take care not to damage the clutch housing and the oil
holes in the end of the shaft when using the puller.
Note: Do not attempt to lever off these components. Always
use the correct tool.
The clutch pack comprises alternate friction plates 24 and
counter plates 25, beginning and ending with a friction plate.
The pack is sandwiched between two spacers 23 and 26,
and secured by circlip 22. Retain these items as a set for
assembly.
Note that the clutch housing cannot be removed from the
shaft.
Discard all seals and O rings.
Inspection
Thoroughly clean all components. Ensure that all oil ways
are clear.
Inspect generally for damage. Check for scoring inside the
piston housing and at the oil feed end of the shaft. Polish out
if necessary.
Check the operation of the non-return valve located in piston
30.
Check the clutch pack for damage and excessive wear.
Replace the complete set of friction and counter plates if
necessary. Do not mix plates from different clutch packs.
Check the condition of brake disc 8. Renew if necessary.
Assembly
Assembly is basically the reverse of the dismantling
sequence, but please note the following.
Use new seals and O rings. Lightly oil components before
installing them.
Pack the cavity between the lips of seal 13 with grease
before assembly.
Thrust washer 28 should be installed using a bearing press,
ensuring that the plate is pressed squarely onto its shoulder
on the shaft. Ring 27 should similarly be installed using a
bearing press.
When installing the clutch pack, ensure that the
friction/counter plates are installed in the correct sequence,
see Dismantling. Note that there are seven friction plates
24, and six counter plates 25. Use the pinion assembly 19 to
align the inner teeth of the friction plates.
Lightly oil bearings 15, 18 and 21 before installing and rotate
them during setting.
After assembly, and using an airline, check that the clutch
operates smoothly and that there is endfloat.
Measure the clutch pack end float using two screwdrivers as
shown at B. The clutch pack endfloat should be 1.3 - 3.6
mm. If incorrect, check for damage, correct assembly and
that the correct number of clutch plates have been installed.
Note that shims are not necessary.
Fitting stake nut 4 may be easier performed after the clutch
has been replaced in the gearbox, see Removal and
Replacement.
Torque Settings
Item
39 47-54 Nm 35-40 lbf ft 4.8-5.5 kgf m
Section F Transmission
9803/7130
Section F
63 - 4
Issue 1
Syncro Shuttle Gearbox
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