Split the tractor between Powershift Transmission and Intermediate housing


Due to the diversity of the hydraulic and mechanical the options available on the tractors, mention will only be made of those the pipes or main connections to be disconnected.
For this reason, before and when disassembling the tractor, ensure no connections remain between the fixed assembly and the moving assembly.
The tractors may be equipped with either a Powershift transmission, or a Heavy transmission.
Disassembly remains basically identical for both versions.

Available equipment fits

- Tractors equipped with Powershift transmission AG150
- Tractors equipped with Powershift transmission AG250
- Tractors equipped with Heavy duty transmission. The cab remains attached to the rear axle.

Disassembling the gearbox and the intermediate housing allows working on the Gerotor hydraulic pump (Powershift transmission) or on the output shaft (Heavy gearbox), located respectively on the rear of the stated gearboxes.
Position the rear wheels in wide tread.
Remove the side panels. Unlock and hinge open the bonnet and remove (if necessary).

Position of locks:
- below the front nose assembly,
- below the front nose assembly, on the rear left-hand side of the bonnet.
Disconnect the tractor battery.
Remove the tractor battery compartment and the right footstep.
Remove the turbocharger guard.
Disconnect the front differential-locking control pipe at both ends (if fitted). Blank the pipe.
Remove the guard and the 4 WD transmission shaft (all tractor types).
Disconnect the charge hose from the brake-master cylinder tank.
Mark then disconnect the steering hoses from the steering unit.
Remove the radiator guards (depending on option).
Disconnect the heating hoses under the right floor of the cab or on the engine (depending on option);
identify their positions. Blank the hoses and ports to prevent complete drainage the cooling system.
Remove the left footstep.
Drain the fuel tanks.

Mark then disconnect:
- the harness to the side-tank gauge,
- the gas-oil supply and return hoses.

Remove the side tank.
Slightly raise the front of the cab and wedge, using suitable axle stands.

Mark positions of following parts then disassemble from the gearbox:
- solenoid valves (if necessary, remove the access door in cab floor to access the upper solenoid valves),
- sensors (intermediate speeds, engine speeds, road speed, gearbox temperature and pressure),
- connectors to receptacles A, B, C, D, E, F of the TC unit installed on the right-hand side of the gearbox.

Drain the intermediate housing.
Disconnect the gearbox return hoses (steering unit, power-assisted braking).
Disconnect the return hose from the brake-master cylinder tank on the intermediate housing.
Disconnect hose (17 bar) towards the power-assisted braking on the right-hand hydraulic cover.
Remove suction pipe at the Gerotor pump, and the elbow unions fitted on the intermediate housing and the Powershift transmission.
Disconnect:
- the creeper-speed control on the right-hand side of the intermediate housing (depending on option, all tractor types)
- the air conditioning intakes at the front left of the cab. Fit blanking plugs.
- the main harness connections above and to the left of the engine.

Disconnect the throttle control on the injection pump.
Block front axle.
Chock the rear wheels.

Separating the gearbox from the intermediate housing.


Fig.1 

In order to free lower shaft (2) (Fig.1), turn the special screw on the Park lock control unit clockwise until a hard point is felt (Powershift transmission only).
Install the disassembly tooling.
Remove the screw attaching the gearbox to the housing.
Assisted by an operator, separate the assemblies, taking care to identify the position of the coupling sleeves on connection shafts (1) and (2) (Fig.2).


Fig.2 

Assembling the gearbox and the intermediate housing

Clean the mating surfaces of the gearbox and the housing.
Coat the mating face of the housing with sealing product Loctite 510 or equivalent.
Check the presence of the locating pins on the housing.
Check the presence of connection shafts (1) and (2) and sleeves (3) (4) (Fig.2).

Position the machined groove on the outside diameter of each sleeve towards the gearbox (optional).

Tractors without creeper speeds, fitted with the Powershift transmission, spring (1) located at the front of shaft (2) maintains the latter in position (Fig.1).

Screw two diametrically opposed guide studs into the gearbox.
Assemble gearbox (8) onto housing (19).
Remove the guide studs. Install screw (1) (Fig.3) and torque to 240 - 320 Nm.


Fig.3

Remove the chocks from the front axle.
Reconnect the throttle control on the injection pump.
Reinstall the left-hand radiator guard (if fitted).


Reconnect:
- the main harness connections above and to the left of the engine,
- the air conditioning intakes at the front left of the cab.

Reinstall:
- the creeper control (if fitted).
- the Gerotor pump sleeves and suction pipe.
Reconnect the power-assisted braking hose (17 bar) on the right-hand hydraulic cover.
Reconnect the return hose from the brake master cylinder tank.
Reconnect the return hoses for the steering unit and power-assisted braking on the gearbox.
Reconnect following items to gearbox:
- connectors for receptacles A, B, C, D, E, F of the TC unit,
- sensors,
- solenoid valves.
Position the cab on its front supports. Install screws in silent blocks and torque to 200 - 270 Nm.
Reinstall the side tank.
Reconnect the following items:
- the gas-oil supply and return hoses,
- the tank-gauge harness.
Reinstall the left footstep.
Reconnect the heating hoses.
Reinstall the right-hand radiator guard (if fitted).
Reconnect the steering hoses on the steering unit.
Reconnect the charge hose to the brake-master cylinder tank.
Reinstall the transmission shaft and guard. Reconnect the differential-locking control pipe (4 WD) (Dana front axles).
Reinstall the battery compartment and right footstep.
Reconnect the tractor battery.
Reinstall the turbocharger guard.
Check the setting of the throttle control.
Service the oil system and check the level in the transparent tube on the left of the center housing.

The drain plug in the intermediate housing is special. It has a cylindrical part which the other plugs do not. It is therefore essential to check its position during reassembly.

Pour fuel into the tanks.
Service the cooling system and the expansion tank.
Reset the special screw on the Park lock control unit to its initial position (Powershift transmission only).
Close the bonnet.
Align the wheels to their initial position. Torque screws or nuts to values shown.
Road test all the controls.
Check the following points:
- leak tightness of hydraulic circuits,
- sealing of mating face between gearbox and intermediate housing,
- operation of electronic and electrical circuits,
- coolant level.

Disassembly method remains basically identical to that used on the version employing the Powershift transmission