10. DISMANTLING IMPACT UNIT - MASTER 35®

1. REMOVING CLUTCH SUPPORT FLANGE 18
Remove Gear Selector 46 and empty oil from Gearbox 30. Remove six Screws holding Clutch Support Flange to Gearbox and pull apart.

2. REMOVING CLUTCH 16 AND MOTOR FLANGE 9
Remove Spark Plug 0060 and fit Piston Stop Tool 10.00022. Turn Clutch Nut 16 in clockwise direction. Loosen two Lock Nuts 12 holding Motor Flange to Motor and pull off Flange. To replace Motor Flange Bearing 13 press out. Assemble in reverse order.

3. REPLACING SEAL 19 & BEARINGS 20 IN CLUTCH SUPPORT FLANGE 18
Remove Circlip 21 and using a soft face mallet tap out Clutch Ring 17. Remove Circlip 22 and from the opposite side push out Bearings 20. Remove Oil Seal 19 and replace if necessary. Assemble in reverse order.

4. DISMANTLING GEARBOX 29
Remove Circlip 27 and lift off Gear 28. Remove Ring Flange 67 and check Bearings 66 & 69 and Oil Seal 68 for wear or damage. Remove Bearing Shaft 42 and check. Remove Circlip 31 and from the opposite side tap out Selector Shaft 33. Using a 5mm Screw extract Planet Pivot 39 by holding the Screw Head in a vice and tap Gearbox with a soft face mallet. Remove Planet Gear 38 and Spacer 36.
Please Note: The Planet Gear has a chamfered edge, which MUST be re-fitted in the same way as before.
Take out Gear Cluster 41 and note directions for re-building. Assemble in reverse order.

5. DISMANTLING HAMMER COMPLETE 78
Place complete Hammer length ways in a vice with hole uppermost. Carefully tighten vice until Steel Ball 76 drops out of lower hole (a short blast of air will assist this operation). Loosen vice and turn Hammer 83 through 180 degrees and repeat previous instruction to allow second ball to be removed. Slowly loosen vice again. Hammer Casing 83 and Catch 71 can now be separated. Remove Shaft 75, Spring 77 and Bearing 74 and inspect for wear. Using Circlip Pliers remove Seeger Rings 79 from Hammer Casing. Tap off Steel Ring 80 with a punch; Knock out four Steel Plugs 82 from inside to allow Cam 81 to be removed from Hammer Casing.
Please Note: Always renew the Steel Plugs before rebuilding.
Inspect Anvil 84 and Hammer 83 striking faces for wear or damage. These are critical areas, which will affect the Wrench's performance. Inspect all parts for wear or damage and replace, grease up and re-build in reverse order. Fit new Gasket 85 and refit Nose Casing 86.
Please Note: It is advisable to replace Seals, 'O' Rings and Gaskets when re-building the Impact Unit.