Repair of AG150/AG250 transmission - Inspecting the transmission components


Inspecting components

Belleville washersCheck for:
- Cracks
- Wear on contact points

Piston, seals and piston boresCheck for:
- Seal hardening, cracking, nicks, etc.
- Piston seal groove: dents, burs, chipping, etc.
- Piston bores: chipping, dents, burs.

Thrust plates and clutch discsCheck for:
- Buckling, heat discoloration, surface and spline wear
Nominal dimensions
- Thrust plates ……… 1.78 mm
- Discs……………… 2.79 mm
When refitting previously used clutch discs and thrust plates, it is the piston travel that determines whether they should be replaced.

Inspection of components
PinionsCheck for:
- Pitting, flaking, ripples, broken teeth, cracks, bore wear due to bearing creep, spline wear.
BearingsCheck for:
- Pitting, denting, grooving, cracks in the groove, wear due to creep on internal and external rims.
Circlips and grooves
Check that circlips and grooves are in good condition.
Circlips with rounded and square edges. The square edge must always retain the load.

ShaftsCheck for:
- Wear on splines, cracks, surface wear due to creep. Check that seal ring grooves are square edged and without burs, etc. That oil channels are not blocked; that all port and stop plugs are correctly in place; that there is no spline wear or cracking in the clutch housings; that circlip slots are square edged.

2nd stage shaft AG 150 transmission

(1) 2nd stage shaft pinion - 71 teeth (2) "A" clutch linings - 10 thrust plates and discs (3) "2" clutch linings - 10 thrust plates and discs (4) "A" clutch hub pinion - 42 teeth Use ATP 3030-1 and ATP 3030-3 sleeves to extract the pinion (5) "2" clutch hub pinion - 48 teeth Use ATP 3030-1 and ATP 3030-6 sleeves to extract the pinion (6) Clutch piston (7) Piston external seal - "D" bush type seal (8) Piston internal seal - O'ring (9) Oil seal washer (10) Belleville washers  (11) Circlip holding washer (12) Circlip
(13) Closing plate (14) Clutch lining circlip (15) "A" clutch internal pinion hub ball bearing (16) "A" clutch external pinion hub ball bearing (17) Circlip (18) Forward shaft roller bearing (19) "2" clutch internal pinion hub ball bearing (20) "2" clutch external pinion hub ball bearing
(21) Circlip (22) Rear shaft ball bearing (23) Lubricating port (24) "2" clutch pressurized oil channel (25) "A" clutch pressurized oil channel (26) Pressurized oil channel

Instructions
(15) The ball bearing may be installed in either position.
(18) The roller bearing must be installed with the bearing circlip facing the centre of the shaft.


2nd stage shaft AG 250 transmission

(1) 2nd stage shaft pinion - 82 teeth (2) "A" clutch linings - 10 thrust plates and discs (3) "2" clutch linings - 10 thrust plates and discs (4) "A" clutch hub pinion - 48 teeth Use ATP 3030-1 and ATP 3030-6 sleeves to extract the pinion (5) "2" clutch hub pinion - 59 teeth Use only ATP 3030-1 sleeve to extract the pinion (6) Clutch piston (7) Piston external seal - "D" bush type seal (8) Piston internal seal - O'ring (9) Oil seal washer (10) Belleville washers  (11) Circlip holding washer (12) Circlip (13) Closing plate (14) Clutch lining circlip (15) "A" clutch internal pinion hub ball bearing (16) "A" clutch external pinion hub ball bearing (17) Circlip (18) Forward shaft roller bearing
(19) "2" clutch internal pinion hub ball bearing (20) "2" clutch external pinion hub ball bearing (21) Circlip (22) Rear shaft ball bearing (23) Lubricating port (24) "2" clutch pressurized oil channel (25) "A" clutch pressurized oil channel (26) Pressurized oil channel

Instructions
(15) The ball bearing may be installed in either position.
(18) The roller bearing must be installed with the bearing circlip facing the centre of the shaft.
(22) The SH2 designation bearing must be installed here. The SH2 bearing is a hardened bearing with twice the normal life span.

3rd stage shaft AG 150 transmission

(1) 3rd stage shaft pinion - 71 teeth (2) "B" clutch linings - 10 thrust plates and discs (3) "R" clutch linings - 10 thrust plates and discs (4) "B" clutch hub pinion - 42 teeth Use only ATP 3030-1 to extract the pinion (5) "R" clutch hub pinion - 62 teeth Use only ATP 3030-1 to extract the pinion
(6) Clutch piston (7) Piston external seal - "D" bush type seal (8) Piston internal seal - O'ring (9) Oil seal washer (10) Belleville washers  (11) Circlip holding washer (12) Circlip (13) Closing plate (14) Clutch lining circlip (15) "B" clutch internal pinion hub ball bearing (16) "B" clutch external pinion hub ball bearing (17) Circlip (18) Front shaft roller bearing
(19) "R" clutch internal pinion hub ball bearing (20) "R" clutch external pinion hub ball bearing (21) Circlip (22) Rear shaft ball bearing (23) Lubricating port (24) "R" clutch pressurized oil channel (25) "B" clutch pressurized oil channel (26) Pressurized oil channel (27) Pinion - 70 teeth (28) Circlip

Instructions
(18) The roller bearing must be installed with the bearing circlip facing the centre of the shaft.



3rd stage shaft AG 250 transmission

(1) 3rd stage shaft pinion - 82 teeth (2) "B" clutch linings - 10 thrust plates and discs (3) "R" clutch linings - 10 thrust plates and discs (4) "B" clutch hub pinion - 48 teeth Use ATP 3030-1 and ATP 3030-6 sleeves to extract the pinion (5) "R" clutch hub pinion - 76 teeth Use only ATP 3030-8 to extract the pinion (6) Clutch piston (7) Piston external seal - "D" bush type seal (8) Piston internal seal - O'ring (9) Oil seal washer (10) Belleville washers  (11) Circlip holding washer (12) Circlip (13) Closing plate
(14) Clutch lining circlip (15) "B" clutch internal pinion hub ball bearing
(16) "B" clutch external pinion hub ball bearing (17) Circlip (18) Forward shaft roller bearing (19) "R" clutch internal pinion hub ball bearing (20) "R" clutch external pinion hub ball bearing (21) Circlip (22) Rear shaft ball bearing (23) Lubricating port (24) "R" clutch pressurized oil channel
(25) "B" clutch pressurized oil channel (26) Pressurized oil channel (27) Pinion - 60 teeth (28) Circlip

Instructions
(16) The SH2 designation bearing must be installed here. The SH2 bearing is a hardened bearing with twice the normal life span.
(18) The roller bearing must be installed with the bearing circlip facing the centre of the shaft.

4th stage shaft AG 150 transmission

(1) 4th stage shaft pinion - 71 teeth (2) "C" clutch linings - 10 thrust plates and discs (3) "1" clutch linings - 10 thrust plates and discs (4) "C" clutch hub pinion - 70 teeth Use only ATP 3030-1 to extract the pinion
(5) "1" clutch hub pinion - 62 teeth Use only ATP 3030-1 to extract the pinion (6) Clutch piston (7) Piston external seal - “D” bush type seal (8) Piston internal seal - O-ring (9) Oil seal washer
(10) Belleville washers – 6 (11) Circlip holding washer (12) Circlip (13) Closing plate (14) Clutch lining circlip (15) "C" clutch internal pinion hub ball bearing (16) "C" clutch external pinion hub ball bearing (17) Circlip (18) Forward shaft roller bearing (19) "R" clutch internal pinion hub ball bearing
(20) "R" clutch external pinion hub ball bearing (21) Circlip (22) Rear shaft ball bearing (23) Lubricating port (24) "1" clutch pressurized oil channel (25) "B" clutch pressurized oil channel (26) Pressurized oil channel

Instructions
(16) The roller bearing must be installed with a circlip in the bearing located towards the front of the shaft
(18) The roller bearing must be installed with the bearing circlip facing the centre of the shaft.



4th stage shaft AG 250 transmission

(1) 4th stage shaft pinion - 82 teeth (2) "C" clutch linings - 10 thrust plates and discs (3) "1" clutch linings - 10 thrust plates and discs (4) "C" clutch hub pinion - 80 teeth Use only ATP 3030-8 to extract the pinion
(5) "1" clutch hub pinion - 76 teeth Use only ATP 3030-1 to extract the pinion (6) Clutch piston (7) Piston external seal - "D" bush type seal (8) Piston internal seal - O'ring (9) Oil seal washer
(10) Belleville washers – 6 (11) Circlip holding washer (12) Circlip (13) Closing plate (14) Clutch lining circlip (15) "C" clutch internal pinion hub ball bearing (16) "C" clutch external pinion hub ball bearing (17) Circlip (18) Forward shaft roller bearing (19) "1" clutch internal pinion hub ball bearing
(20) "1" clutch external pinion hub ball bearing (21) Circlip
(22) Rear shaft ball bearing - hardened bearing (23) Lubricating port (24) "1" clutch pressurized oil channel (25) "C" clutch pressurized oil channel (26
Pressurized oil channel

Instructions
(15) The SH2 designation bearing must be installed here. The SH2 bearing is a hardened bearing with twice the normal life span.
(16) The roller bearing must be installed with a circlip in the bearing located towards the front of the shaft.
(18) The roller bearing must be installed with the bearing circlip facing the centre of the shaft.
(22) The SH2 designation bearing must be installed here. The SH2 bearing is a hardened bearing with twice the normal life span.