Repair of AG150/AG250 transmission - Reassembling the clutch


Reassembling the speed clutch train
Place the clutch train vertically on the bench. Refit the internal and external seals on piston. Smear the piston seals and clutch-housing bore with transmission oil. Fit the piston with the pockets and grooves on the outside. Install an oil seal washer (9). All the clutch oil seal washers are identical. Reassemble the Belleville washers (10). The diameter of the first Belleville washer must be in contact with the oil seal washer. The second Belleville washer must be in contact with the external diameter of the first washer. Alternate the Belleville washers until they are all installed.

(6) Piston (9) Washer - oil stop (10) Belleville washers (12) Circlip holding washer and circlip.


Place the clutch train on a press. Using tool ATP 3002 compress the Belleville washers and fit a holding washer and a circlip.
Before assembly, lubricate the thrust plates and discs with transmission oil. Alternate 10 thrust plates with 10 discs, beginning with a thrust plate on the piston. Fit the closing plate and circlip.

Measuring piston travel
- Using a depth gauge, measure distance (A) from the end of the piston to the edge of the clutch housing.
- Inject compressed air at 4.8 bars into the piston supply channel to compress the Belleville washers.
- Measure distance (B) from the end of 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 intermediate plates since their thickness
varies.
. With new thrust plates and discs:
Piston travel - 1.3 - 3.8 mm
. With used thrust plates and discs:
Piston travel - 1.8 - 5.5 mm

Reassembling clutch bearings
Certain bearings used in the clutches and shafts require installing in the correct direction.
- Reassemble bearing (15) the nearest to the clutch linings, using the ATP 3020 sleeve.


- Reassemble the pinion with the clutch hub (4) in the discs or thrust plates and above the bearing (15). The pinion is slid over the bearing. Turn and lightly shake the pinion until all the splines of the discs and thrust plates are engaged and bearing (15) is at the bottom of the bore of the pinion.



- Reassemble the external pinion hub bearing (16) on the shaft and push it into the pinion hub. Fit the circlip on the shaft.
- Place the extractor on the pinion (4), pull the pinion and bearing (16) against circlip to eliminate any lateral load being placed on the bearings.


The pinion hub must move longitudinally.
- Install the shaft bearing on the shaft and push it into its emplacement.
- Repeat the procedure for each end of the shaft and for all the other speed clutch shafts.

Input shaft - 1st stage shaft 


AG 150 transmission
(1) 1st stage shaft - 32 teeth (2) At the rear - roller bearing (3) At the front - ball bearing.
Instructions
(2) Install the roller bearing with the bearing circlip facing the pinion.

AG 250 transmission
(1) 1st stage shaft - 38 teeth (2) At the rear - roller bearing (3) At the front - ball bearing.
Instructions
(2) Install the roller bearing with the circlip facing the pinion.

Repairing the first stage shaft
- Remove the clutch train support tool required to reach and extract the input shaft.
- Check for damage to the input shaft (1) and bearings (2) and (3) and replace where necessary.
- Place the split bearing extractor (OEM 4175 or equivalent) on the bearing. Use the appropriate extractor to hook the bearings and remove them from the input shaft.
- Push new bearings (2) and (3) into their emplacement using an appropriate sleeve tool.
- Replace the input shaft (1) in the support tool and replace the clutch trains in the reverse order of their removal.