Repair of AG150/AG250 transmission - Repairing the range clutch shaft


- All gear range clutch trains are dismantled in the same way.
- All the gear trains possess a clutch.
- The gear range clutch trains are identified as follows:

"L" clutch - 5th stage shaft
"H" clutch - 6th stage shaft
"M" clutch - 7th stage shaft

Take care that the shaft is properly supported to avoid toppling and damage to the pinions.
- Install a suitable split bearing extractor (OEM 4175 or equivalent) on the first bearing. The split bearing extractor must be placed in such a manner that its flat surface is turned towards the pinion. Tighten the extractor bolts until the bearing begins to extract from the 7th stage shaft.


- Hook the pinion extractor beneath the split bearing extractor and remove the bearing from the shaft by pulling. Remove the circlips (20) from the shaft.
- Place the pinion extractor sleeve (ATP 3030) on the pinion and tighten the bolts. To be able to extract the pinion from the shaft, the extractor sleeve must be tightened around the external diameter of the pinion. In certain cases, use of the main sleeve is specified and must be fitted beneath the pinion. Hook the pinion extractor beneath the extractor sleeve and remove the pinion and bearingfrom the shaft by pulling upwards.

- Take off circlip (12) and closing plate (11), the thrust plates, clutch discs and clutch housing.
- Place a suitable pinion extractor on the internal pinion bearing (13) and remove it from the shaft.


- Place the clutch train in a press. Place tool ATP 3002 on the Belleville washers. Compress the washers, remove circlip and release the pressure on the washers.
- Remove the clutch train from the press and take off the holding washer of circlip (9) and Belleville washers (8) from the clutch.



- Remove the oil seal washer located between the Belleville washers (8) and the clutch piston.
- Once all the Belleville washers are removed, feed compressed air into the clutch pressurized oil channel, near shaft seal ring. This will eject the piston from the clutch housing.
- Disassemble the opposite end of the shaft in the same manner.
The best method of supporting the shaft is to have a 76 mm diameter hole in the workbench to receive the shaft.
- Compress the Belleville washers and remove the circlip using tool ATP 3002.
- Take off the washing retaining the circlip, the Belleville washers and the oil seal washer.
- Remove the clutch piston.


5th stage shaft 

AG 150 transmission
(1) 5th stage pinion shaft - 74 teeth (2) "L" clutch linings - 10 thrust plates and discs (3) Pinion "L" clutch hub - 40 teeth. Use extractor sleeves ATP 3030-1 and ATP 3030-10 to remove the pinion. (4) Clutch piston (5) External piston seal - type "D" bush seal (6) Internal piston seal - O’ring
(7) Oil seal washer (8) Belleville washers  (9) Circlip retaining washer (10) Circlip (11) Closing plate (12) Clutch lining circlip (13) Protected ball bearing of "L"clutch internal pinion hub (14) Ball bearing of "L"clutch external pinion hub (15) Clutch lubricating oil regulation O’ring
(16) Forward shaft ball bearing (17) Rear shaft roller bearing (18) Circlip (19) Circlip (22) "L" clutch pressurized oil channel (23) Pressurized oil channel (24) Lubricating port

Instructions
(13) The protected ball bearing must be installed with the protective device facing the clutch linings.
(17) The roller bearing must be installed with the bearing circlip facing the centre of the shaft



5th stage shaft 

AG 250 transmission
(1) 5th stage pinion shaft - 80 teeth (2) "L" clutch linings - 10 thrust plates and discs (3) Pinion "L" clutch hub - 44 teeth. Use extractor sleeves ATP 3030-1 and ATP 3030-12 to remove the pinion. (4) Clutch piston (5) External piston seal - type "D" bush seal (6) Internal piston seal - O’ring
(7) Oil seal washer (8) Belleville washers  (9) Circlip retaining washer (10) Circlip (11) Closing plate (12) Clutch lining circlip (13) Protected ball bearing of "L" clutch internal pinion hub (14) Ball bearing of "L" clutch external pinion hub (15) Clutch lubricating oil regulation O’ring
(16) Forward shaft ball bearing - hardened bearing (17) Rear shaft roller bearing (18) Circlip (19) Circlip (22) "L" clutch pressurized oil channel (23) Pressurized oil channel (24) Lubricating port

Instructions
(13) The protected ball bearing must be installed with the protective device facing the clutch linings.
(16) The SH2 bearing must be installed here. The SH2 bearing is a hardened bearing providing twice the normal life span.
(17) The roller bearing must be installed with the bearing circlip facing the centre of the shaft

6th stage shaft 

AG 150 transmission
(1) 6th stage pinion shaft - 72 teeth (2) "H" clutch linings - 10 thrust plates and discs (3) Pinion - "H" clutch hub - 48 teeth. Use extractor sleeves ATP 3030-1 and ATP 3030-155 to remove the pinion. (4) Clutch piston (5) External piston seal - type "D" bush seal (6) Internal piston seal - O’ring
(7) Oil seal washer (8) Belleville washers  (9) Circlip retaining washer (10) Circlip (11) Closing plate (12) Clutch lining circlip (13) Protected ball bearing of "H" clutch internal pinion hub (14) Ball bearing of "H" clutch external pinion hub (15) Clutch lubricating oil regulation O’ring
(16) Forward shaft ball bearing (17) Rear shaft roller bearing (20) Circlip (21) Distance piece sleeve (22) "H" clutch pressurized oil channel (23) Pressurized oil channel (24) Lubricating port

Instructions
(13) The protected ball bearing must be installed with the protective device facing the clutch linings.



6th stage shaft 

AG 250 transmission
(1) 5th stage pinion shaft - 81 teeth (2) "H" clutch linings - 10 thrust plates and discs (3) Pinion "H" clutch hub - 53 teeth. Use extractor sleeves ATP 3030-1 and ATP 3030-16 to remove the pinion. (4) Clutch piston (5) External piston seal - type "D" bush seal (6) Internal piston seal - O’ring (7) Oil seal washer (8) Belleville washers (9) Circlip retaining washer (10) Circlip (11) Closing plate (12) Clutch lining circlip (13) Protected ball bearing of "H" clutch internal pinion hub (14) Ball bearing of "H" clutch external pinion hub (15) Clutch lubricating oil regulation O’ring (16) Forward shaft ball bearing - hardened bearing (17) Rear shaft roller bearing - hardened bearing (20) Circlip (21) Distance piece sleeve (22) "H" clutch pressurized oil channel (23) Pressurized oil channel (24) Lubricating port

Instructions
(13) The protected ball bearing must be installed with the protective device facing the clutch linings.
(16) The SH2 bearing must be installed here. The SH2 bearing is a hardened bearing providing twice the normal life span.
(17) The SH2 bearing must be installed here. The SH2 bearing is a hardened bearing providing twice the normal life span.

7th stage shaft 

AG 150 transmission
(1) 7th stage pinion shaft - 65 teeth (2) "M" clutch linings - 10 thrust plates and discs (3) Pinion "M" clutch hub - 40 teeth. Use extractor sleeves ATP 3030-1 and ATP 3030-10 to remove the pinion. (4) Clutch piston (5) External piston seal - type "D" bush seal (6) Internal piston seal - O’ring (7) Oil seal washer (8) Belleville washers (9) Circlip retaining washer (10) Circlip (11) Closing plate (12) Clutch lining circlip (13) Protected ball bearing of "M" clutch internal pinion hub (14) Ball bearing of "M" clutch external pinion hub (15) Clutch lubricating oil regulation O’ring (16) Forward shaft ball bearing (17) Rear shaft roller bearing (18) Circlip (22) "M" clutch pressurized oil channel (23) Pressurized oil channel (24) Lubricating port

Instructions
(13) The protected ball bearing must be installed with the protective device facing the clutch linings.



7th stage shaft 

AG 250 transmission
(1) 7th stage pinion shaft - 75 teeth (2) "M" clutch linings - 10 thrust plates and discs (3) Pinion "M" clutch hub - 47 teeth. Use extractor sleeves ATP 3030-1 and ATP 3030-13 to remove the pinion. (4) Clutch piston (5) External piston seal - type "D" bush seal (6) Internal piston seal - O’ring
(7) Oil seal washer (8) Belleville washers  (9) Circlip retaining washer (10) Circlip (11) Closing plate (12) Clutch lining circlip (13) Protected ball bearing of "M" clutch internal pinion hub (14) Ball bearing of "M" clutch external pinion hub (15) Clutch lubricating oil regulation O’ring (16) Forward shaft ball bearing - hardened bearing (17) Rear shaft roller bearing - hardened bearing
(18) Circlip (22) "M" clutch pressurized oil channel (23) Pressurized oil channel (24) Lubricating port

Instructions
(13) The protected ball bearing must be installed with the protective device facing the clutch linings.
(16) The SH2 bearing must be installed here. The SH2 bearing is a hardened bearing providing twice the normal lifetime
(17) The SH2 bearing must be installed here. The SH2 bearing is a hardened bearing providing twice the normal lifetime

Assembling range clutches
- Place the clutch train vertically on the workbench. Install the internal and external seals on the piston (4). Smear the piston seals and clutch-housing bore with transmission oil. Fit piston (4) with the reinforcements and depressions facing outside.
- Install an oil seal washer (7). All the clutch oil seal washers of the range are identical.
- Install a Belleville washer (8). The first washer closest to the piston must touch the internal rim of the washer. The second Belleville washer must touch the external rim of the first washer. Alternate Belleville washers until they are all installed.


(4) Piston
(7) Oil seal washer
(8) Belleville washers
(10) Circlip

- Place the clutch train in a press. Using tool ATP 3002, compress the Belleville washers and fit retaining washer and a circlip (10).
- Lubricate the thrust plates and discs with transmission oil as they are installed. Begin with the thrust plate closest to the piston and alternate until the 10 thrust plates and 10 friction disks are installed. Place the splined clutch closing plate on the outside and fit circlip.

Measuring piston travel
- Using slide callipers fitted with a depth gauge, measure distance A from the piston to the edge of the clutch housing.
- Inject 4.8 bar compressed air in the oil channel to compress the Belleville washers. Measure distance from the piston to the edge of the clutch housing.
- The difference between these two measurements, A - B equals the piston travel.

Piston travel
- The piston travel can be adjusted by selecting or exchanging thrust plates since their thickness varies.
. With new clutch discs and thrust plates
Piston travel: 1.3 to 3.8 mm
. With used clutch discs and thrust plates
Piston travel: 1.8 to 5.5 mm

Reassembling clutch range bearings
Certain bearings used in the clutches and on the shafts are directional and must be installed in the correct direction. 
- Push bearing (13) the closest to the clutch linings, on to the shaft using a compression tool (ATP 3020). Install the bearing with the protective device facing the clutch lining.


- Install the oil regulation o’ring (15) on clutch hub and lubricate the o’ring.


- Install the pinion with the clutch hub (3) in the discs and thrust plates, over the bearing. The pinion being placed above the bearing. Turn the pinion and shake lightly so that all the splines of the discs and thrust plates are correctly engaged and so that the bearing thrusts against the bottom of the pinion bore.


When fitting the hub, ensure that the oil regulation O’ring (15) is not pinched when it passes the closing plate. The O’ring must be positioned so that it is loose on the clutch hub.
- Install external pinion hub bearing (14) on the shaft using a compression tool (ATP 3020) and push it into the pinion hub. Install a circlip on the shaft of the fifth or seventh stage, or a sleeve and a circlip on the sixth stage shaft.


- Place an extraction sleeve (ATP 3030) on the pinion, pull the pinion and the bearing upwards against the circlip to avoid any lateral load on the bearings. The hub of the pinion must move longitudinally.
- Place the bearings on the shaft and push them home using a compression tool (ATP 3020).
Bearing of the fifth stage clutch train is a roller bearing and must be installed so that the bearing circlip faces the clutch.
- Repeat the procedure at each end of the shaft and for all the speed clutch shafts.