GEARBOX AND CLUTCH

MECHANICAL VEHICLE DRIVE CLUTCH

GEARBOX

Technical support Chapter

00 11 354 320 – Edition 09.2007

GB
MECHANICAL VEHICLE DRIVE CLUTCH

GB
 CONTENTS

RECONDITIONING:POWER MEASUREMENT (KW)MECHANICAL VEHICLE DRIVE CLUTCH

GB
GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH
MECHANICAL VEHICLE DRIVE CLUTCH

Help with servicing

Tools
Specific tooling
Reference:Power measurement (kW)60 05 005 900
Designation:Power measurement (kW)Hub with stop
Scene:

Specific tooling
Reference:Power measurement (kW)77 01 388 424
Designation:Power measurement (kW)Centring spacer
Scene:

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Specific tooling
Reference:Power measurement (kW)77 01 388 430
Designation:Power measurement (kW)Rigging template
Scene:

Specific tooling
Reference:Power measurement (kW)77 01 388 433
Designation:Power measurement (kW)Clutch housing trolley
Scene:

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Special tool
Reference:Power measurement (kW)77 01 388 435
Designation:Power measurement (kW)Centering spindle
Scene:

Ingredients
Standard ingredients
Refer to the tightness and attachment products at the beginning of the document.

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Exploded view
PTO and vehicle drive clutch

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Tractors Vehicle drive pressure plate

Tractors Diaphragm + junction
Clutch cover Power take-off pressure plate
Vehicle drive friction plate Power take-off friction plate

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Mechanical controls for vehicle drive and PTO clutch

TWINSHIFT gearbox Power take-off end stop mount

Manual gearbox Clutch guide
Vehicle drive shaft Power take-off control fork assembly
Power take-off shaft Vehicle drive control fork assembly
Vehicle drive release bearing Seal
Power take-off release bearing Circlip
Vehicle drive end stop mount Attachment

Torque settings
Standard tightening torque
Refer to the standard tightening torques at the beginning of the document

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Specific tightening torque

Clutch

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Flywheel. Engine flywheel attachment screw.

Clutch cover. Clutch cover attachment screw.
Vehicle drive friction plate. Vehicle drive shaft.
Vehicle drive pressure plate. Power take-off forward.
Diaphragm + junction. Vehicle drive release bearing.
Power take-off pressure plate. Power take-off release bearing.
Power take-off friction plate. Vehicle drive end stop mount.
Vehicle drive release levers. Power take-off end stop mount.
Power take-off release levers. Clutch guide.
Power take-off release lever adjusting screw. Vehicle drive control fork assembly.
Vehicle drive release lever adjusting screw. Power take-off control fork assembly.
Drive release lever locknut. Bearing.
Locating pin.

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Main operations

Removal:Power measurement (kW)Clutch

Note: As the clutch is fairly heavy, special tool
n° should be used to ensure safe removal. In
all cases, an appropriate lifting system must be used.
Disconnect the tractor between the engine and gearbox. See
work card: Engine change.
Make marks at and to identify the position of the
clutch in relation to the engine flywheel.
Remove the clutch attachments and detach the clutch from
the flywheel.
Check flywheel condition. See work card: Reconditioning the
engine flywheel.

Dismantling:Power measurement (kW)Clutch

IMPORTANT: Before removing the clutch, the relative
position of the plates must be marked.
Make a mark on the PTO plate and a mark on the vehicle
drive plate in relation to the clutch cover (Fig. ).

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Mark the three vehicle drive clutch release levers and the
three PTO release levers in relation to the clutch cover
as illustrated.
When dismantling take care not to lose the pins .
HP tractor.

Check:Power measurement (kW)Friction disks

Check minimum thickness and maximum run-out of the friction discs in the vehicle drive clutch and PTO clutch .
Replace them when the these values fall outside the limits shown below.

Ref Disc thickness Nominal Minimum

Vehicle drive From to (mm) mm
PTO From to (mm) mm

Refitting:Power measurement (kW)Clutch

Refit in the reverse order to dismantling, respecting the markings made before removal..

Refitting:Power measurement (kW)Clutch

Refit in the reverse order to dismantling, respecting the markings made before removal..
Note: As a safety precaution, the lifting gear used for removal must be used when refitting.
Tighten the clutch attachments to a torque of:

Screw diameter (mm)

Torque settings (daN.m)

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Adjustment:Power measurement (kW)Clutch release levers

Fit the centring tool n° on the thrust hub n° with the sleeve n° , insert the rigging
template n° .
Note: The template fitted is calibrated to the dimension of the release levers.
Press the template against the flywheel as shown in the figure below
Tighten the three PTO release lever nuts until resistance is felt taking care not to move the template (Use a thin shim).
Lock the nuts using .
Tighten the three screws on the vehicle drive release levers until resistence is felt then tighten the lock nuts taking
care not to move the template(Use a thin shim). Lock the nuts using .
Re-attach the gearbox casing to the engine crankcase
Re-tighten the casing attachments to a torque of to daN.m.

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Removal:Power measurement (kW)Clutch release bearings and guide

Note: The operations described below apply to all types of
mechanically controlled clutch.
Disconnect the tractor between the engine and gearbox.
Free the release bearing operating arms.
Advance the release bearings by manually operating the
controls and .
Remove the two fasteners attaching the vehicle drive
fork to the vehicle drive release bearing support .

Remove the two fasteners attaching the PTO fork to the PTO release bearing support .
Extract both release bearing supports and by sliding them forwards along the clutch guide .
Remove the vehicle drive release bearing .
Remove the PTO release bearing support by sliding it along the vehicle drive release bearing support .
Remove the PTO release bearing .
Remove the clutch guide by extracting its attachment screws.
Extract the seal fitted on the forward drive shaft .

Refitting:Power measurement (kW)Clutch release bearings and guide

Proceed in reverse order to dismantling.
Replace the seal .
Refit the clutch guide to the gearbox casing, tightening its attachment screws to a torque of daN.m.
Reassemble the operating arms on the clutch levers and .
Adjust the controls if required.

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Adjustment:Power measurement (kW)Wheel drive mechanical clutch clearance

Set the upper position of the pedals at mm from the mat.
Adjust the length of the push rod to the dimension of about mm.
If replacing the entire clutch unit (clutch/cable), preset the cable by allowing the threaded rod to protrude mm.
With the pedal already adjusted, operate the lever to bring the fork into contact with the clutch plate.
Adjust nut until it contacts lever .
Insert a mm adjusting shim between the nut and the lever
Adjust nut until it contacts lever .
Withdraw the adjusting shim
Tighten nut against lever .
Check that the clutch pedal free play is about mm.

GB
 RECONDITIONING
MECHANICAL VEHICLE DRIVE CLUTCH

Fork operating lever. Operating rod.

Fork. Rod Pedal position in relation to the carpet: mm.
Adjustment screws (clearance).

GB
GEARBOX

GB
 CONTENTS

RECONDITIONING:POWER MEASUREMENT (KW)REVERSHIFT INPUT UNIT ............................................1

RECONDITIONING:POWER MEASUREMENT (KW)TWINSHIFT INPUT UNIT .............................................41

RECONDITIONING:POWER MEASUREMENT (KW)DOUBLER AND MECHANICAL REVERSER .............70

RECONDITIONING:POWER MEASUREMENT (KW)GEARBOX AND RANGES...........................................81

GB
GB
 RECONDITIONING
REVERSHIFT INPUT UNIT
REVERSHIFT INPUT UNIT

Help with servicing

Tools
Specific tooling
Reference:Power measurement (kW)60 05 006 107
Designation:Power measurement (kW)Skena "Revershift"
Scene:

Specific tooling
Reference:Power measurement (kW)60 05 006 151
Designation:Power measurement (kW)Dummy piston for dismantling and inspecting the dual range unit brake
Scene:

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Specific tooling
Reference:Power measurement (kW)60 05 006 153
Designation:Power measurement (kW)Compression tool
Scene:

Locally made tool

Designation:Power measurement (kW)Tool for checking splitter brake
Scene:

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Locally made tool

Designation:Power measurement (kW)Drive shaft bearing exctractor.
Scene:

For use with a claw extractor - Diameter to mm.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Locally made tool

Designation:Power measurement (kW)Piston spring compressor tool

Scene:

For use with a claw extractor - Diameter to mm.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Locally made tool

Designation:Power measurement (kW)Lip seal insertion tool
Scene:

Ingredients
Standard ingredients
Refer to the tightness and attachment products at the beginning of the document.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Exploded view
planet gear dual range unit

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Dual range unit brake. Backplate.

Dual range unit planet gears. Friction disks.
Dual range unit clutch. Piston support plate.
Needle roller/thrust ball bearings. Belleville washers.
Input unit. Shim.
Brake piston. Washers.
O-ring. Needle roller/thrust ball bearings.
O-ring. Washer.
Screw. tooth sun gear.
Guide. tooth sun gear.
Circlips. Needle roller/thrust ball bearings.
Clutch piston. and tooth double planetary gear.
Seal. Needle cage.
O-ring. Spacers.
Belleville washers. Pin.
Circlip. Pin.
Backplate. Thick backplate.
Friction disks. Needle bearing.
Circlip.
Needle roller/thrust ball bearings.
Washer.
Unit.
Planet-carrier unit.
Circlip.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Reverser and clutches

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Reverser Circlip.
Reverse gear clutch ( to depending on engine power) Deflector.
Forward gear clutch ( to depending on engine power) Belleville washers.
Unit. O-ring.
Needle bearing. O-ring.
Link shaft. Piston.
Shims. Supply cover.
Needle roller/thrust ball bearings. Screw.
Washer. Nozzle.
Washers. Plug.
Splined hub. Circlip.
tooth sun gear. Shaft.
Needle roller/thrust ball bearings. Needle roller/thrust ball bearings.
Needle roller/thrust ball bearings. Splined hub.
Washer. Shim.
and tooth double planetary gear. Needle bearing.
Needle cage. Needle roller/thrust ball bearings.
Spacer. Circlip.
Pin. Blanking plate.
Pin. Splined hub.
tooth reverser planet gear. Backplate.
Needle cage. Friction disks.
Spacer. Pin.
Pin. Spring.
Pin. Circlip.
Needle roller/thrust ball bearings. Deflector.
Washer. Belleville washers.
Backplate. O-ring.
Friction disks. O-ring.
Pin. Piston.
Spring. Clutch housing.
O-ring.
Input unit.
Screw.

Torque settings
Standard tightening torque
Refer to "Tightening torques" at the beginning of this chapter.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Specific tightening torque

Adjustments and torque settings

Power supply unit attachment screw:

screws / ± daN.m
Verbus screws / ± daN.m
Belleville washers (Stalling under daN stress)

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Casings tightening torque and sealing

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Access box housing and engine housing Tightness torques of screws on cover:
Access box housings and gearboxes With Revershift: daN.m
Front and rear axle gearbox sumps Without Revershift: daN.m ± Loctite

Main operations

Removal:Power measurement (kW)Revershift input unit

Note: Slacken the clutch housing screws before
decoupling the tractor to facilitate undoing the casing
screws.
Remove the cab. See work card: Refitting the cab.
Drain the transmission hydraulic system.
Remove the Revershift hydraulic unit.
Remove the hydraulic supply hoses from the Revershift
unit

Split the engine and the clutch housing.

Refer to the work card in chapter : Replacing the engine.
Remove the circlips and the shim at the end of the PTO shaft
(PTO clutch side).
Remove the PTO shaft.
Remove the clutch housing and place it upright.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Remove the screws and slacken of the

diametrically opposed screws .
Replace with screws to bear down on
the casing and extract the unit.
Install a lifting chain and remove the unit.
Carefully extract the entire unit.

Carefully extract the entire unit.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Dismantling:Power measurement (kW)Hydraulic dual range unit

Dismantling the dual range unit clutch
Remove the HM screws from the front cover to release it.
Extract the clutch assembly.
Extract circlip and withdraw the friction plates and backplates, circlip to remove the Belleville washers .

Dismantling the dual range unit brake

Compress the Belleville washers using the dummy piston tool
n° .
Note: Tool n° may be used with tool
n° fitted upside down.
Remove the circlip, the backplates and the disks.
Note: Mark the piston in relation to the cover before
removing it.
Remove the piston.
Note: Change the O-rings, applying grease when fitting.

Dismantling the dual range unit planet gears

xtract the unit and the needle roller/thrust ball bearings as well as washer .
Recover the foil washers .
Extract the pins .
Then remove the double pinion assembly.
Extract the needle roller/thrust ball bearings and the satellite pinions.

Refitting:Power measurement (kW)Dual range unit planet gears

All parts must be oiled before reinstallation.
All seals must be replaced
Fit the needle roller/thrust ball bearing , followed by the
washer .
Take care to line up the holes in the washers when
refitting them.
Note: Use paint to mark the two teeth on which there
are "punch marks" , to facillitate satellite
synchronisation.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Adjustment of dual range unit planet gears ( planet gears)

Fit double planet gears ensuring they are the right way round. Position the paint marks as shown in the illustration.

teeth visible inside the casing

tooth visible from outside the casing, the other being
hidden

Fit the sun gear without moving the planet gears.

Fir the last dual planet gears, ensuring they are the right way round.
Fit the sun gear without moving the planet gears.
Fit the needle roller/thrust ball bearings .
Check for free rotation of the unit by turning the planet gears by hand and checking their position times (see previous
illustration).
Fit the needle roller/thrust ball bearing , then washer into the casing .

Adjustment of dual range unit planet gears ( planet gears)

Position the tooth sun gear and paint a mark on one tooth. Position planet gear number so that the marked tooth on the
sun gear is between the two punch marks on the planet gear.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Planet gear number

Punch mark (manufacturer) on planet gears
Paint mark (repairer) on sun gear
tooth sun gear
Planet-carrier unit

Fit planet gear number then turn the sun gear turns.
Position planet gear number so that the marked tooth on the
sun gear is between the two punch marks on the planet gear.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Fit planet gear number then turn the sun gear turns.
Position planet gear number so that the marked tooth on the
sun gear is between the two punch marks on the planet gear.

Fit planet gear number then turn the sun gear turns.
Position planet gear number so that the marked tooth on the
sun gear is between the two punch marks on the planet gear.

Fit planet gear number then turn the sun gear turns.
IMPORTANT: The marked sun gear tooth must be located
between the two punch marks on the first planet gear ,
or the setting will have to be repeated (item ).

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Refitting:Power measurement (kW)Dual range unit brake

Note: If the dual range unit brake piston is being replaced,
turn it as shown in the diagram to facilitate fitting the
cover.

Carry out a trial installation to determine the shim setting

required later.
In the casing , install the two Belleville washers,
respecting the orientation.
IMPORTANT: Carry out the following operations carefully
when refitting the dual range unit brake to avoid damage.

Fit backplate number (thickness mm) as shown in the

diagram. One of the notches in the backplate must fit into the
orifice located between the two most widely spaced drillings.
: The shortest distance between drillings in the
casing.
: The greatest distance between drillings in the
casing.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Fit backplate number (thickness mm) as shown in the

diagram.
Fit the 2st disk.

Fit backplate number (thickness mm) as shown in the

diagram. Two of the notches on the back plate must be located
opposite the two most widely spaced drillings.
Fit the 2nd disk.

Fit backplate number (thickness mm) as shown in the

diagram.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Dual range unit brake

IMPORTANT: If changing disks and back plates, there is no
need to adjust shims at the Belleville washers. However
this adjustment must be made when changing the
Belleville washers.
Fit the rule n° .

Position tool n° so as to compress the

Belleville washers.
Note: Take care to use the correct notches when installing
the tool.
Place the assembly under a press.
Note: Tool n° may be used with tool
n° fitted upside down.
Compress the Belleville washers to a value of daN.m for
the insertion of the Belleville washers.

Position the rule n° in the circlip groove .

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Reduce the force by daN.m.

Carry out the following adjustment:
Using a depth gauge measure dimension .
The thickness of the rule is mm.
Dimension is determined from the seating face of the circlip to the seating face of the friction back plate.
= -
. is a manufacturer's dimension that is dependent on the mechanical characteristics of the Belleville washers (for a force of
daN: . = mm
= -
Shim dimension is intended to generate sufficient pressure on the friction disks via the Belleville washers. Inadequate shim
thickness leads to a risk of slippage in the friction disks through lack of pressure. Excessive shim thickness may lead to the unit
turning continuously.
Hence:
= -
Example:
If: = mm
Then: = mm
Shims available ( - - ).
Use a mm shim.
Dismantle the unit again to insert the appropriate thickness of shim, then rebuild the unit.
Refit the Belleville washers the right way round.
To reinsert the circlip, use tool n° to apply pressure to the unit.
Reinstall the piston using new seals and .

GB
RECONDITIONING
REVERSHIFT INPUT UNIT

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Refitting:Power measurement (kW)Hydraulic dual range unit

Refit the piston on the guide .
The seals and must be changed.
Refit the Belleville washers the right way round. Refit the circlip .
Refit the Belleville washers and the friction discs on the guide then lock with the circlip .
The seals must be changed and refitted to the guide.

Check:Power measurement (kW)Dual range unit brake

Note: This check is carried out with the clutch dual range
unit removed.
Use a locally manufactured tool and the torque setting
wrench.
Under zero force (not subject to press), the brake must not
slip when one applies, using the torque setting wrench, a torque
equal to the following values:
planet gear dual range unit: daN.m
planet gear dual range unit: daN.m

Check:Power measurement (kW)Dual range unit clutch

Using the press, apply a force of daN.
With the clutch installed, it must be possible to turn the friction
disks (Maximum torque daN.m).

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Dismantling:Power measurement (kW)Reverser and reverse clutch

Identify and remove the cover .
Place the cover under the press using tool n° , compress the Belleville washers in order to remove the
circlip and the deflector .
Extract the piston .
If necessary, replace the washers.
Remove the friction disks and the back plates .
Remove the splined shaft.
Remove the reverser unit.
Dismantle the reverser unit.

Check:Power measurement (kW)Oil jet: Reverse gear clutch

When dismantling, check that the oil jet on the reverse
gear clutch is not blocked.

Refitting:Power measurement (kW)Reverser

IMPORTANT: Make a paint mark on the teeth marked with
'punch marks' to facilitate the synchronisation of the
planet gears.
Fit the two friction washers inside the planet-carrier
housing making sure they are the right way round.
Fit the twin planet gears using the larger of the drillings then
the reversal planet gears using the smaller diameter drillings.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Position the paint marks as shown in the illustration.

mark on each side of the centre line

tooth on the centre line
Large drilling
Small drilling
Marking visible on only one of the two sides

Fit the shaft , the sun gear including the needle roller/thrust ball bearings and and the washer .
Fit the washer , needle roller/thrust ball bearings and the shim(s) .
Check operation of the unit by rotating it several times.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Reverse gear clutch

Measure with a depth gauge.

Measure dimension with a depth gauge (Piston face to

mounting surface).

Stack the back plates and friction disks .

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Using a hydraulic press apply a force of daN to the unit.

Note: The force must be evenly distributed over the entire
surface.

Measure (Between the base and the upper back

plate ).

Calculate dimension :
= - -

Depending on the number and type of friction disk, dimension may adopt certain well defined values (see table below):

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

NUMBER OF DIMENSION MUST EQUAL

FRICTION DISCS
(Worn disk) (New and worn disk) (New disk)
± mm ± mm
± mm ± mm
± mm ± mm

Note: If dimension is outside tolerance, the back plates can be changed (Two thicknesses are available:
and mm).

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Reverser

The shim thickness is calculated by measuring dimension and dimension .
= -( + )
The clearance required is ± mm.

Use a depth gauge or dial gauge to take the measurements.

The mechanical reverser assembly has to be rebuilt to assess
shim requirements.
Example:
= - = mm
mm is the thickness of the rule .

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

To obtain dimension , measure dimensions and .

= - = mm
Calculate the shim thickness .
= -( + )
± mm

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Refitting:Power measurement (kW)Reverser and reverse clutch

Reassemble the reverser and reverse clutch assembly, using new seals throughout.
Lightly lubricate the seals before installation.
Insert the appropriate shim thickness.
Refit the cover and tighten the screws to a torque of ± daN.m.
Oil the attachment screws.

Dismantling:Power measurement (kW)Forward clutch

Remove the circlip .
Remove the closing plate .
Remove the friction disks and the back plates .
Position the clutch housing under a press and compress the Belleville washers in order to be able to remove the
circlip and the deflector .
Extract the piston .
If necessary, replace the washers.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Forward gear clutch

Fir the circlip ensuring that it is at its upper stop.

Measure (thickness of circlip).

Measure dimension with a depth gauge. This is the
dimension that separates the upper surface of the circlip and
the piston face.

Stack the back plates , the friction disks and the

closure plate on perfectly flat and smooth surface .

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Using a hydraulic press apply a force of daN to the unit.

Note: The force must be evenly distributed over the entire
surface.
Measure . This is the dimension between the base and
the closure plate .

Calculate dimension :
= - -

Depending on the number and type of friction disk, dimension may adopt certain well defined values (see table below):

NUMBER OF DIMENSION MUST EQUAL

FRICTION DISCS
(Worn disk) (New and worn disk) (New disk)
± mm ± mm
± mm ± mm

Note: If dimension is outside tolerance, the back plates can be changed (Two thicknesses are available:
and mm).

Refitting:Power measurement (kW)Forward gear clutch

Refit the piston with new O-ring seals.
Refit the Belleville washers the right way round.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Using a press, fit the circlip and the deflector .

Refit the friction disks and back plates .
Fit the blanking plate .
Refit the circlip .

Check:Power measurement (kW)Forward gear clutch

After the rebuild, check that the inner hub turns freely.
It if does not, fit a mm back plate in place of the mm one
or vise versa.

Adjustment:Power measurement (kW)Forward gear clutch

Refit the supply unit on the primary shaft.
Refit the forward gear clutch assembly.
Refit the reverse gear and dual range assembly.
Note: This setting is also used when installing with the
crawl function.
Extract the shims located inside the splined shaft .

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Ensure that the combined bearing is installed reversed before checking the dimensions.
This bearing cannot in fact be removed without damage.

The shim thickness is calculated by measuring dimension

and dimension . Using a depth gauge, measure
dimensions and .
Calculate the shim thickness using the following formula:
= - - ±
The backlash should be between and mm.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Measure dimension
= - = mm
mm is the thickness of the rule.

Measure dimension
= mm

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Measure dimension at different locations and take the

smallest value.
= - = mm
mm is the thickness of the rule.
= - = - = mm
= - - ±
= - - ±
= to mm
The shims to be fitted should have a thickness of to
mm.
Install the shims under the combined bearing mounted
the right way round.

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Refitting:Power measurement (kW)Revershift unit

IMPORTANT: To facilitate the mating of the clutch housing
to the gear box, ensure that the hub is correctly in
place on the forward gear clutch.
Refit the clutch housing.

Change the seals on the Revershift hydraulic unit.

Torque settings for the forward and reverse gear solenoid
valves:
Solenoid valve on hydraulic unit: daN.m (- ; + )
Coil on solenoid valve: Solenoid valve on hydraulic unit:
daN.m (- ; + )

GB
 RECONDITIONING
REVERSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Speed sensor

Coat the thread of the sensor with Loctite n° .
Screw down the sensor until it contacts the Revershift unit
Slacken of a turn to obtain the correct gap.
Gently tighten the locknut.

GB
RECONDITIONING
REVERSHIFT INPUT UNIT

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT
TWINSHIFT INPUT UNIT

Help with servicing

Tools
Specific tooling
Reference:Power measurement (kW)60 05 006 105
Designation:Power measurement (kW)Avdragare och insättare av stoppring (används med verktyg nr )
Scene:

Specific tooling
Reference:Power measurement (kW)60 05 006 107
Designation:Power measurement (kW)Skena "Revershift"
Scene:

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Specific tooling
Reference:Power measurement (kW)60 05 006 151
Designation:Power measurement (kW)Dummy piston for dismantling and inspecting the dual range unit brake
Scene:

Locally made tool

Designation:Power measurement (kW)Synchro adjustment gauge
Scene:

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Locally made tool

Designation:Power measurement (kW)Synchro adjustment gauge
Scene:

Locally made tool

Designation:Power measurement (kW)Synchro adjustment gauge
Scene:

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Locally made tool

Designation:Power measurement (kW)Tool for checking splitter brake
Scene:

Ingredients
Standard ingredients
Refer to the tightness and attachment products at the beginning of the document.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Exploded view
Hydraulic dual range unit ( planet gears)

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Dual range unit assembly. Planet-carrier unit.

Input unit. Circlip.
Brake piston. Backplate.
Inner O-ring. Friction disks.
Outer O-ring. Piston support plate.
Screw. Belleville washers.
Guide. Shim.
Rings. Washers.
Clutch piston. Needle roller/thrust ball bearings.
Inner seal. Washer.
Outer seal. tooth sun gear.
Belleville washers. tooth sun gear.
Circlip. Needle roller/thrust ball bearings.
Backplate. and tooth double planetary gear.
Friction disks. Needle cage.
Circlip. Spacer.
Needle roller/thrust ball bearings. Pin.
Washer. Pin.
Unit. Plate.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Mechanical reverser

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Planet-carrier unit. Pin.

Link shaft. Flange.
Needle bearing. Cover.
Shims. Washer.
Needle roller/thrust ball bearings. Needle roller/thrust ball bearings.
Washer. Washer.
Washers. Screw.
tooth sun gear. Sliding gear.
tooth sun gear. Synchro hub.
Needle roller/thrust ball bearings. Spring.
Needle roller/thrust ball bearings. Hollow keys.
and tooth double planetary gear. Synchro ring.
Needle cage. Synchro ring.
Spacer. Synchro ring.
Pin. Needle roller/thrust ball bearings.
Pin. Differential hub.
tooth reverser planet gear. Shim.
Needle cage.. Needle cage.
Spacer.
Pin.

Torque settings
Standard tightening torque
Refer to "Tightening torques" at the beginning of this chapter.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Specific tightening torque

Adjustments and torque settings

Hydraulic supply Power supply unit attachment screw:

Multidisc brakes screws / ± daN.m
planet gear dual range unit Verbus screws / ± daN.m
Mechanical reverser Vehicle drive shaft
Belleville washers (Stalling under daN stress) Link shaft
Hydraulically-actuated multidisc clutches Primary shaft

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Casings tightening torque and sealing

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Access box housing and engine housing Tightness torques of screws on cover:
Access box housings and gearboxes With Revershift: daN.m
Front and rear axle gearbox sumps Without Revershift: daN.m ± Loctite

Main operations

Removal:Power measurement (kW)TWINSHIFT unit

Slacken the clutch housing screws before decoupling the tractor to facilitate undoing the casing screws.
Remove the cab:
See work card: Refitting the cab.
Drain the hydraulic system.
Remove the LH hydraulic cover.
Split the tractor at the clutch:
See work card: Replacing the engine.
Remove the circlips and the shim at the end of the PTO shaft (PTO clutch side).
Remove the PTO shaft.
Remove the two hydraulic supply lines from the Twinshift unit.
Remove the clutch housing and place it upright.
Remove the Verbus screws .
Slacken diametrically opposed screws out of the HM screws.
Replace with screws to bear down on the casing and extract the unit.
Attach a chain.

Carefully extract the entire unit.

Dismantling:Power measurement (kW)Hydraulic dual range unit

Dismantling the dual range unit clutch
Mark the cover in relation to the unit.
Remove the HM screws on the front cover and extract it.
Extract the clutch assembly.
Extract circlip and withdraw the friction plates and backplates, circlip to remove the Belleville washers .

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Dismantling the dual range unit brake

Compress the Belleville washers using the dummy piston tool
n° .
Note: Tool n° may be used with tool
n° fitted upside down.
Remove the circlip, the backplates and the disks.
Note: Mark the piston in relation to the cover before
removing it.
Remove the piston.
Note: Change the O-rings, applying grease when fitting.

Dismantling the dual range unit planet gears

xtract the unit and the needle roller/thrust ball bearings as well as washer .
Recover the foil washers .
Extract the pins .
Then remove the double pinion assembly.
Extract the needle roller/thrust ball bearings and the satellite pinions.

Refitting:Power measurement (kW)Dual range unit planet gears

All parts must be oiled before reinstallation.
All seals must be replaced
Fit the needle roller/thrust ball bearing , followed by the
washer .
Take care to line up the holes in the washers when
refitting them.
Note: Use paint to mark the two teeth on which there
are "punch marks" , to facillitate satellite
synchronisation.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Adjustment of dual range unit planet gears ( planet gears)

Fit double planet gears ensuring they are the right way round. Position the paint marks as shown in the illustration.

teeth visible inside the casing

tooth visible from outside the casing, the other being
hidden
Fit the sun gear without moving the planet gears.
Fir the last dual planet gears, ensuring they are the right way round.
Fit the sun gear without moving the planet gears.
Fit the needle roller/thrust ball bearings .
Check for free rotation of the unit by turning the planet gears by hand and checking their position times (see previous
illustration).
Fit the needle roller/thrust ball bearing , then washer into the casing .

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Adjustment of dual range unit planet gears ( planet gears)

Position the tooth sun gear and paint a mark on one tooth. Position planet gear number so that the marked tooth on the
sun gear is between the two punch marks on the planet gear.

Planet gear number

Punch mark (manufacturer) on planet gears
Paint mark (repairer) on sun gear
tooth sun gear
Planet-carrier unit

Turn the tooth satellite gear turns.

Position the 2nd planet so that the marked tooth on the sun
gear is between the two punch marks on the planet gear.
Turn the tooth satellite gear turns.

Position the 3rd planet gear so that the marked tooth on the
satellite gear is between the two punch marks on the planet
gear.
Turn the tooth satellite gear turns.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Position the planet gear so that the marked tooth on the

satellite gear is between the two punch marks on the planet
gear.
Turn the tooth satellite gear turns.

IMPORTANT: The marked sun gear tooth must be located

between the two punch marks on the first planet gear ,
or the setting will have to be repeated (item ).

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Refitting:Power measurement (kW)Dual range unit brake

Carry out a trial installation to determine the shim setting
required later.
In the casing , install the two Belleville washers,
respecting the orientation.
IMPORTANT: Carry out the following operations carefully
when refitting the dual range unit brake to avoid damage.

Fit backplate number (thickness mm) as shown in the

diagram. One of the notches in the backplate must fit into the
orifice located between the two most widely spaced drillings.
: The shortest distance between drillings in the
casing.
: The greatest distance between drillings in the
casing.

Fit backplate number (thickness mm) as shown in the

diagram.
Fit the 2st disk.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Fit backplate number (thickness mm) as shown in the

diagram. Two of the notches on the back plate must be located
opposite the two most widely spaced drillings.
Fit the 2nd disk.

Fit backplate number (thickness mm) as shown in the

diagram.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Dual range unit brake

IMPORTANT: If changing disks and back plates, there is no
need to adjust shims at the Belleville washers. However
this adjustment must be made when changing the
Belleville washers.
Fit the rule n° .

Position tool n° so as to compress the

Belleville washers.
Note: Take care to use the correct notches when installing
the tool.
Place the assembly under a press.
Note: Tool n° may be used with tool
n° fitted upside down.
Compress the Belleville washers to a value of daN.m for
the insertion of the Belleville washers.

Position the rule n° in the circlip groove .

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Reduce the force by daN.m.

Carry out the following adjustment:
Using a depth gauge measure dimension .
The thickness of the rule is mm.
Dimension is determined from the seating face of the circlip to the seating face of the friction back plate.
= -
is a manufacturer's dimension that is dependent on the mechanical characteristics of the Belleville washers (for a force of
daN: . = mm
= -
Shim dimension is intended to generate sufficient pressure on the friction disks via the Belleville washers. Inadequate shim
thickness leads to a risk of slippage in the friction disks through lack of pressure. Excessive shim thickness may lead to the unit
turning continuously.
Hence:
= -
Example:
If: = mm
Then: = mm
Shims available ( - - ).
Use a mm shim.
Dismantle the unit again to insert the appropriate thickness of shim, then rebuild the unit.
Refit the Belleville washers the right way round.
To reinsert the circlip, use tool n° to apply pressure to the unit.
Reinstall the piston using new seals and .

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Refitting:Power measurement (kW)Hydraulic dual range unit

Refit the piston on the guide .
The seals and must be changed.
Refit the Belleville washers the right way round. Refit the circlip .
Refit the Belleville washers and the friction discs on the guide then lock with the circlip .
The seals must be changed and refitted to the guide.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Check:Power measurement (kW)Dual range unit brake

Note: This check is carried out with the clutch dual range
unit removed.
Use the dual drive unit brake checking tool and a torque
setting wrench.
Under zero force (not subject to press), the brake must not
slip when one applies, using the torque setting wrench, a torque
equal to the following values:
planet gear dual range unit: daN.m
planet gear dual range unit: daN.m

Check:Power measurement (kW)Dual range unit clutch

Using the press, apply a force of daN.
With the clutch installed, it must be possible to turn the friction
disks (Maximum torque daN.m).

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Drive shaft bearing

The endfloat should be ± mm.
Shim adjustment can only be carried out when the input unit is fixed to the dual drive unit.
Insert the baering, fit the circlip.
Measure the dimensions:
: Depth between the outer face of the input unit and the bearing mating surface.
: Depth between the outer face of the input unit and the pressure surface of the circlip in its housing.
: Thickness of circlip.
Determine shim thickness :
= -( + + )

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Dismantling:Power measurement (kW)Reverser

Mark the cover before removal.
Remove the reverser unit.
Dismantle the reverser unit.

Refitting:Power measurement (kW)Reverser

IMPORTANT: Make a paint mark on the teeth marked with
'punch marks' to facilitate the synchronisation of the
planet gears.
Fit the two friction washers inside the planet-carrier
housing making sure they are the right way round.
Fit the twin planet gears using the larger of the drillings then
the reversal planet gears using the smaller diameter drillings.

Position the paint marks as shown in the illustration.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

mark on each side of the centre line

tooth on the centre line
Large drilling
Small drilling
Marking visible on only one of the two sides

Fit the satellite gears and inserting the needle roller/thrust ball bearings and .
Fit the washers and and the needle roller/thrust ball bearings .
Check operation of the unit by rotating it several times.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Adjustment:Power measurement (kW)Reverser

Only adjust this setting on units fitted with a screw-on cover.
The floating cover does not special adjustment.
The shim thickness is calculated by measuring dimension and dimension :
: Dimension between the casing mating surface and the shaft bearing.
: Dimension between the mating surface of the thrust bearing and the mating surface of the cover .
The shim value equals:
= - - (within a tolerance of mm)
is the float value to be applied

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Measure dimension
Use tool n° .
Measure dimension with a depth gauge.
Subtract the thickness of the bar, or mm.
Take at least measurements at diametrically opposed
positions and take the mean value of the .

Measure dimension
measurements are needed to determine :
= -

Use tool n° .
Measure dimension with a depth gauge.
Take at least measurements at diametrically opposed positions and take the mean value of the .
Position a feeler gauge on the needle roller thrust bearing to provide a level surface for the measurement of .
Use tool n° .
Add the thickness of the feeler gauge used when taking the measurement to the value recorded to obtain .
Take at least measurements at diametrically opposed positions and take the mean value of the .
Final reassembly
Insert the shims required to achieve the previously calculated setting.

GB
 RECONDITIONING
TWINSHIFT INPUT UNIT

Insert the reverser assembly into the housing .

Tighten the screws to a torque of ± daN.m.

Adjustment:Power measurement (kW)Synchronisation clearance for the reverser

The functional clearance is ± mm.
Use locally manufactured tools .
Record the dimensions before refitting the input unit cover, the brake and clutch to ensure correct seating of the dual range
unit.
The shim value equals:
= - -
Or:
= +
= +
Hence:
= - - (within a tolerance of mm)

GB
RECONDITIONING
TWINSHIFT INPUT UNIT

GB
RECONDITIONING
TWINSHIFT INPUT UNIT

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER
DOUBLER AND MECHANICAL REVERSER

Help with servicing

Ingredients
Standard ingredients
Refer to the tightness and attachment products at the beginning of the document.

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Exploded view
Input unit without doubler with mechanical reverser

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Vehicle drive clutch shaft. Sleeve.

tooth pinion. Tapered roller bearing.
Needle cage. Clutch guide.
Thrust bearing. Screw.
Tapered roller bearing. Counter shaft.
Sliding gear. Tapered roller bearing.
Synchro ring. tooth pinion.
Synchro ring. Spacer.
Cotter. tooth pinion.
Spring. Spacer.
Tapered roller bearing. Tapered roller bearing.
tooth pinion. Shim.
Link shaft. Circlip.

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Input unit with reverser and mechanical doubler (With crawl range)

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Vehicle drive clutch shaft. Screw.

tooth pinion. Counter shaft.
Needle cage. Tapered roller bearing.
Shims. tooth pinion.
Tapered roller bearing. Spacer.
Sliding gear. tooth pinion.
Synchro ring. Spacer.
Synchro ring. tooth pinion.
Cotter. Tapered roller bearing.
Spring. Shim.
Tapered roller bearing. Circlip.
Bush. Counter shaft.
tooth pinion. tooth pinion.
Needle cage. Needle cage.
Synchro hub. Washer.
Sliding gear. Pin.
Synchro ring. Pin.
Synchro ring. Needle cage.
Cotter. Planet carrier.
Spring. Shim.
tooth pinion. Screw.
Needle cage. Unit.
Link shaft. Sliding gear.
Sleeve. External circlip.
Tapered roller bearing. Planet gear.
Lip seal. Crown wheel.

Torque settings
Standard tightening torque
Refer to "Tightening torques" at the beginning of this chapter.

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Specific tightening torque

Casings tightening torque and sealing

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Access box housing and engine housing Tightness torques of screws on cover:
Access box housings and gearboxes With Revershift: daN.m
Front and rear axle gearbox sumps Without Revershift: daN.m ± Loctite

Main operations

Preparation:Power measurement (kW)Preliminary operations

Remove the cab:
Refer to the work card in chapter : Refitting the cab.
Disconnect the clutch housing from the engine:
Refer to the work card in chapter : Replacing the engine.
Separate the clutch housing from the gearbox housing:
Refer to the work card in chapter : Refurbishing ratio and range change gearbox.

Adjustment:Power measurement (kW)Clutch shaft

The required preload is between and mm maximum.
Shimming is applied at . The thickness of the shim at is fixed ( mm).
Refit the shaft with a mm shim at and a mm shim at .
Pull on the shaft while turning it alternately clockwise and anticlockwise to properly seat the bearings.
Remove the circlip and the shim .
Measure .
Refit the circlip.
Measure .
: Depth between the outer face of the clutch housing and the bearing contact face.
: Depth between the outer face of the clutch housing and the contact face of the circlip when installed in its groove.
: Thickness of circlip.
Determine shim thickness :
= -( + )
Add mm of preload shims.

GB
RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Preload check
There must be no play in the shaft.
Wrap a cord around the reverser sliding gear.
The force, measured using a spring balance, must be between and daN (Via the left aperture in the clutch housing).
IMPORTANT: The measurement must be carried out:
Without counter shaft
Without reverser gear train
Without primary shaft

Adjustment:Power measurement (kW)Reverser/doubler gear train

The asymmetric gears are installed with the longer skirt towards the front face of the clutch housing.
Remove the shims.
Measure the axial backlash using a dial gauge.
Depending on the backlash measured, select a shim thickness to obtain a preload of between and mm.

GB
 RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

Adjustment:Power measurement (kW)Mechanical reverser countershaft

Remove the shims.
Measure the axial backlash using a dial gauge.
Depending on the backlash measured, select a shim thickness to obtain a preload of between and mm.

GB
RECONDITIONING
DOUBLER AND MECHANICAL REVERSER

GB
 RECONDITIONING
GEARBOX AND RANGES
GEARBOX AND RANGES

Help with servicing

Tools
Specific tooling
Reference:Power measurement (kW)77 01 388 516
Designation:Power measurement (kW)Calibration shim for setting the conical distance of mm
Scene:

Specific tooling
Reference:Power measurement (kW)77 01 388 552
Designation:Power measurement (kW)Primary shaft extractor
Scene:

Ingredients
Standard ingredients
Refer to the tightness and attachment products at the beginning of the document.

GB
 RECONDITIONING
GEARBOX AND RANGES

Exploded view
Primary gear train - Primary shaft

GB
 RECONDITIONING
GEARBOX AND RANGES

Gearbox without low range Cotter.

Gearbox with low range Synchro hub.
Washer. Sliding gear.
Washer. Synchro ring.
Tapered roller bearing. Synchro ring.
Primary shaft. Synchro ring.
Needle cage. Pinion.
Pinion. Plain bush.
Synchro ring. Needle cage.
Spring. Plain bush.

GB
 RECONDITIONING
GEARBOX AND RANGES

Primary gear train - Rear intermediate shaft

GB
 RECONDITIONING
GEARBOX AND RANGES

Synchro hub. Rear intermediate shaft.

Spring. Needle bearing.
Cotter. Seal.
Sliding gear. Tapered roller bearing.
Synchro ring. Shim (Thicknesses available : ).
Tapered roller bearing. Internal circlip.
Pinion.
Cylindrical bearing.

GB
 RECONDITIONING
GEARBOX AND RANGES

Secondary gear train - Front intermediate shaft

GB
 RECONDITIONING
GEARBOX AND RANGES

Internal circlip. Synchro ring.

Shim (Thicknesses available : ). Synchro ring.
Tapered roller bearing. Synchro ring.
Bush. Pinion.
Needle cage. Bush.
Pinion. Needle cage
Synchro ring. Pinion.
Synchro ring. Spacer.
Synchro ring. Pinion.
Spring. Spacer.
Cotter. Pinion.
Synchro hub. Needle bearing.
Sliding gear. Tapered roller bearing.

GB
 RECONDITIONING
GEARBOX AND RANGES

Secondary gear train - Secondary shaft

GB
 RECONDITIONING
GEARBOX AND RANGES

Drive pinion. Nut.

Synchro ring. Plain pinion.
Cotter. Shim (Thicknesses available :
Spring. ).
Synchro hub. Dual taper bearing.
Pinion. Cover.
Needle cage. Drive pinion.
Pinion.

Torque settings
Standard tightening torque
Refer to "Tightening torques" at the beginning of this chapter.

GB
 RECONDITIONING
GEARBOX AND RANGES

Specific tightening torque

Casings tightening torque and sealing

GB
 RECONDITIONING
GEARBOX AND RANGES

Access box housing and engine housing Tightness torques of screws on cover:
Access box housings and gearboxes With Revershift: daN.m
Front and rear axle gearbox sumps Without Revershift: daN.m ± Loctite

GB
 RECONDITIONING
GEARBOX AND RANGES

Main operations

Preparation:Power measurement (kW)Removal of the gearbox

Remove the cab:
See work card: Refitting the cab.
Remove the PTO unit:
Refer to the work card in chapter : Refurbishment of PTO unit.
Split the engine and the clutch housing:
Refer to the work card in chapter : Replacing the engine.
Remove the clutch limit stops and controls.
Remove the shafts and forks from the input unit.
Remove the input unit.
Remove the cover plates from the main gearbox.
Split the tractor between the gearbox and the rear axle.
Note: If a synchro ring is to be changed, there is no need to separate the gearbox from the rear axle. The complete
primary shaft has to be withdrawn forwards.

Removal:Power measurement (kW)Primary shaft

The difference between the types of primary shaft lie mainly in the shaft and synchro units. The synchro units may be single or
double depending on the version.
Remove the fork shafts, the forks and and rd/ th and th gear selectors.
Remove the lubrication lines.
If the tractor is fitted with the crawler speed option, remove the step-down gear unit.
See overall and exploded views for the full dismantling of the primary shaft.
To extract the primary shaft, use tool n° .
Use a slide hammer.
As the shaft is withdrawn, extract the 5th gear synchro unit and the bearing cone.
Then extract the rd gear pinion, the synchro unit and the th gear pinion.
Note: The th gear pinion on the rear intermediate shaft may be removed if required.

GB
 RECONDITIONING
GEARBOX AND RANGES

Washer. Synchro ring.

Washer. Synchro ring.
Tapered roller bearing. Pinion.
Primary shaft. Plain bush.
Needle cage. Needle cage.
Pinion. Synchro hub.
Synchro ring. Spring.
Spring. Cotter.
Cotter. Sliding gear.
Synchro hub. Synchro ring.
Sliding gear. Tapered roller bearing.
Synchro ring. Pinion.

Removal:Power measurement (kW)Rear intermediate shaft

Remove the circlip and the shims .

GB
 RECONDITIONING
GEARBOX AND RANGES

Always replace the O-ring seal .

Removal:Power measurement (kW)Secondary gear train

Remove the shafts and forks for 1st/2nd gear.
Remove the lubrication line at the end of the shaft.
Using a slide hammer, remove the secondary shaft assembly.
Remove the front intermediate shaft:
Strike the end of the shaft using a bronze drift and remove it from the rear of the box.
Recover components as the unit is extracted.
Note: If the secondary shaft is being replaced, the rear axle crown wheel must be replaced.

Adjustment:Power measurement (kW)PTO intermediate shaft

Adjust shimming on the tapered bearings in the bare casing.
Remove the PTO intermediate shaft.
Check and clean the parts.

Casing Tapered roller bearing

Circlip Pinion
Shim Tapered roller bearing

GB
 RECONDITIONING
GEARBOX AND RANGES

Position the casing vertically.

Fit the tapered bearing and pinion assembly in the casing.
Measure dimension after having pushed the assembly in
the direction shown .

Fit the circlip then measure dimension after having

pushed the taper bearing against the circlip.
Measure the thickness of the circlip .

Calculate the float between the circlip and the outer race of
the bearing:
= - -
Determine the shim thickness to obtain a preload:
= +
Check the preload torque .
must be between and N.m.
Add or remove the equivalent of a mm shim to obtain the
correct preload.

GB
 RECONDITIONING
GEARBOX AND RANGES

Refitting:Power measurement (kW)Primary gear train

Check and clean the parts.
Replace any defective components.
Check correct operation of all components.
Refit the primary shaft with its taper bearing.
Make sure that the 5th gear synchro hub is installed the right way round.
Refit the rear intermediate shaft.
Replace the shims and the circlip.
Refit the supply unit for the hydraulic reverser or the cover on the low range unit on the primary shaft.

Gearbox without low range or hydraulic reverser

Insert the washer on the shaft on completion of the rebuild.
Refit the clamp and tighten its attachments to a torque of ± daN.m.
Note: Pull on the shaft while turning it alternately clockwise and anticlockwise to properly seat the bearings..

Adjustment:Power measurement (kW)Rear intermediate shaft bearings

Adjustment is made to the rear intermediate shaft of the primary gear train. Adjustment must be carried out before the
secondary gear train is refitted.
Wrap a cord around the rear intermediate shaft.
Using a n° spring balance, pull on the cord until the shaft starts to rotate.
The primary shaft must be held stationary.
Measure the corresponding force .
This must be between and daN for the tooth pinion and between and daN for the tooth pinion.
If the force required falls outside these limits, repeat the adjustment operations and change the shims, then repeat the check:
Increase shim thickness if the force is too low.
Reduce shim thickness if the force is too high.
Continue until the force obtained is correct.

GB
 RECONDITIONING
GEARBOX AND RANGES

Removal:Power measurement (kW)Primary gear train

Re-dismantle the primary gear train so that the secondary gear train can be adjusted.
Record the shim thickness used on the rear intermediate shaft for the final re-assembly.

Dismantling:Power measurement (kW)Secondary shaft

Extract the baering cone , then the synchro unit and the pinions to give access to the nut .
Unlock and unscrew the nut then extract the dual taper bearing .
Recover the shim(s) .
Replace any faulty component.
IMPORTANT: The dual taper bearing is pre-adjusted; it must not be dismantled.

GB
 RECONDITIONING
GEARBOX AND RANGES

Refitting:Power measurement (kW)Secondary shaft

Carry out refitting in the opposite order of removal.

GB
 RECONDITIONING
GEARBOX AND RANGES

Adjustment:Cone distance
Note: The theoretical cone distance ( theoretical) is
mm. Using shims this distance can be adjusted in
accordance with the manufracturer's data marked on the
bevel gears.

The theoretical cone distance is measured using gauge

block .
IMPORTANT: Before any measurement, replace the cover
over the dual taper bearing to ensure correct seating.

GB
 RECONDITIONING
GEARBOX AND RANGES

Check marking and calculating adjustment value

Marking datums on the input pinion, crown wheel and on the
rear axle boss enables calculation of the corrections (in
millimeters) to be applied to the cone distance as a function of
actual dimensions of the components. These corrections
enable the determination of the value of the cone distance
setting ( ).
The mark , the same as on the input pinion and the
crown wheel ensures that they are installed as a pair.
Mark , on the input pinion, must not be used
(Manufacturer's mark).
Mark , where present, corresponds to the value in
hundreds of a millimetre to be subtracted to obtain the
adjustment figure .

Mark , located on the right side of the rear axle,

corresponds to the value in hundreds of a millimetre to be
subtracted (- sign) or added (+ sign) to obtain the adjustment
figure .

Examples of the calculation of the cone distance setting

Calculate the cone distance setting :

(On the front face of the input (On the boss on the right of the (cone distance setting, to be
pinion) rear axle) calculated)
No indication = mm
No indication = + = mm
= - - =
No indication = - = mm

GB
 RECONDITIONING
GEARBOX AND RANGES

Practical adjustment
Refit the dual taper bearing on the shaft without the shims.
Replace the secondary shaft so that the cone distance can be
adjusted.
Record the values of the corrections to be applied and .
Calculate the cone distance setting ( ).
Using the dial gauge and its mount , measure the distance
( measurement) between the raw cone distance and the
theoretical cone distance using gauge block
n° :
= -
The thickness of shim required is equal to the su of the
following deviations:
=( - )+
Example:
= mm
= - = mm
= mm
=( - )+ = mm
In this example, shim thickness to be used is mm.
Record the shim setting for the secondary shaft for use during
final assembly.
Re-dismantle the shaft and dual taper bearing.

Refitting:Power measurement (kW)Front intermediate shaft

Clean all parts and examine carefully.
Replace any defective element.
Oil bearings and rotating components.
Start by replacing the taper bearing in the casing bearing housing.
Proceed in reverse order to dismantling.
IMPORTANT: All dual synchro cones must be lubricated.

Adjustment:Power measurement (kW)Dual taper bearing

Refit the secondary shaft.
Insert the shims required to achieve the previously calculated setting.
Carry out an initial tightening of nut to a torque of ± daN.m and turn the bevel gear to seat the bearings.
Carry out a second tightening to ± daN.m and turn the bevel gear.
Fold over the skirt of the nut to lock it.

GB
 RECONDITIONING
GEARBOX AND RANGES

Adjustment:Power measurement (kW)Front intermediate shaft

The preload required is to mm.
The cone distance on the secondary shaft must be adjusted first.
After fitting the shaft without shims, place a dial gauge against the end of the shaft (Fig. ) so as to measure the
movement of the shaft.
Pull on the shaft while rotating it backwards and forwards to "seat" the cones in the bearing cups .
Set the dial gauge to zero.
Push on the shaft while rotating it backwards and forwards to "seat" the cones in the bearing cups .
Measure (Shaft movement).
The shimming required equals:
if the bearings are used.
+ - if the bearings are new.

Refitting:Power measurement (kW)Primary gear train

Oil all rotating components before refitting.
All dual taper synchro units must be soaked in oil before refitting.

GB
 RECONDITIONING
GEARBOX AND RANGES

Refit the primary shaft with its taper bearing.

Make sure that the 5th gear synchro hub is installed the right way round.
Refit the rear intermediate shaft.
Install the thickness of shims as measured and the circlip.
Depending on equipment fit:
Refit the supply unit for the hydraulic reverser or the cover on the low range unit on the primary shaft.
Insert the washer on the shaft on completion of the rebuild.
Refit the clamp and tighten its attachments to a torque of ± daN.m.

Pull on the shaft while turning it alternately clockwise and anticlockwise to properly seat the bearings.
Refit the oil line at the end of the shaft.
Refit the fork shafts, the forks and the rd/ th and th gear change selectors.

Adjustment:Power measurement (kW)Forks (ratios 1, 2, 3 and 4)

Fit a flat plate to compress the springs and plungers on the
forks.
Position a dial gauge on the end of the shaft of the fork to be
adjusted (example : ratios and ).
Select the synchro to neutral.
Engage a gear ratio (example : ratio ).
Measure the axial backlash using a dial gauge.
Engage the other ratio (example : ratio ).
Measure the backlash.
Take the mean of the two readings.
Where necessary, offset the fork in relation to its shaft by:
Tightening screw and slackening screw .
Slackening screw and tightening screw .
The setting is attained when the mean value is obtained on
the dial gauge.
Repeat the same operation on the synchro unit for the 3rd and
4th gear ratios.
Adjustment of the 5th gear ratio and the ranges is achieved
using a set of feeler gauges positioned between the sliding gear
and the fork. The same value of backlash must be obtained on
each side.
Note: Check that there is backlash between the fork and
the sliding gear to avoid friction and premature wear in the
syncho bushes.

Refitting:Power measurement (kW)Final steps

Refit the covers to the gearbox.
Re-connect the rear axle to the gaerbox.
Re-connect the gearbox to the engine casing.
Refit the input unit.
Refit the controls, the shafts and forks in the input unit.
Refit the clutch limit stops and controls.
Re-connect the gearbox to the engine casing.
Refit the PTO gearbox.

GB
 RECONDITIONING
GEARBOX AND RANGES

Refit the front axle transmission shaft.

Refit the cab. See work card: Cab replacement.

GB