R2900G Load Haul Dump Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

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Illustration 1	g01059489

1. Lower the temperature of bearing (37) (not shown). Use Tooling (A) to install sleeve bearing (37) to spider assembly (35). Sleeve bearing (37) must be even with the outside surface of spider assembly (35).

   Note: Lubricate the bore of bearing (37) with the lubricant that is being sealed.

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   Illustration 2	g01059492

2. Install spider assembly (35) to housing (15).

3. Install bolts (34). Tighten bolts (34) evenly to a torque of 120 ± 15 N·m (90 ± 11 lb ft).
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   Illustration 3	g01059493

   Note: Lubricate bearing (33) with the lubricant that is being sealed.

4. Install two thrust bearing races (32) and thrust bearing (33) to housing (15).
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   Illustration 4	g01054587

5. Install retaining ring (31) to hub (28).
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   Illustration 5	g01059756

6. Install turbine (27) to hub (28).

7. Install bolt retainer (30) to turbine (27).

8. Install the bolts from the opposite side of hub (28) to bolt retainer (30). Tighten the bolts evenly to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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   Illustration 6	g01054582

9. Install hub (28) and turbine (27) as a unit to housing (15).
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   Illustration 7	g01059765

10. Check the clearance between the turbine and the housing. For new components the clearance dimension (U) across the diameter must be 2.67 ± 0.38 mm (0.105 ± 0.015 inch). For worn components the maximum permissible clearance across the diameter is 4.001 mm (0.1575 inch).
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    Illustration 8	g01059798

    Note: Lubricate bearing (26) with the lubricant that is being sealed.

11. Install two thrust bearing races (25) and thrust bearing (26) to the hub.
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    Illustration 9	g01059800

12. Use Tooling (A) to install sleeve bearing (24) (not shown) to carrier assembly (20). Bearing sleeve (24) must be even with the counterbore of carrier assembly (20).

    Note: Lubricate the bore of bearing (24) with the lubricant that is being sealed.

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    Illustration 10	g01054579

13. Install retainer ring (23) to stator (22).
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    Illustration 11	g01059803

14. Position carrier assembly (20) on a wood block.

15. Raise the temperature of stator (22). Install stator (22) to carrier assembly (20).
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    Illustration 12	g01059804

16. Install snap ring (21) to stator (22).
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    Illustration 13	g01059806

17. Install stator (22) and carrier assembly (20) to housing (15).
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    Illustration 14	g01059807

18. Check the clearance between the stator and the turbine. For new components, the clearance dimension (V) must be 0.81 ± 0.10 mm (0.032 ± 0.004 inch). For worn components the maximum permissible clearance across the diameter is 1.22 mm (0.048 inch).
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    Illustration 15	g01059808

    Note: Lubricate bearing (19) with the lubricant that is being sealed.

19. Install two thrust bearing races (18) and thrust bearing (19) to the carrier assembly.
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    Illustration 16	g01059816

20. Install impeller (13) and hub (16) to drive flange (17).

21. Install the bolts through hub (16) to the drive flange. Tighten the bolts evenly to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 17	g01059813

22. Check the clearance between the impeller and the stator. For new components the clearance, dimension (W) must be 0.81 ± 0.10 mm (0.032 ± 0.004 inch). For worn components the maximum permissible clearance across the diameter is 1.22 mm (0.048 inch).
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    Illustration 18	g01059817

23. Install impeller (13) to housing (15).
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    Illustration 19	g01054150

24. Install 36 bolts (12) and the washers. Tighten the bolts evenly to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 20	g01059819

25. Install retaining ring (10) to drive gear (9).
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    Illustration 21	g01059820

26. Lower the temperature of outer bearing race (11).

27. Install outer bearing race (11) to drive gear (9). Make sure that outer bearing race (11) makes contact with retaining ring (10).
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    Illustration 22	g01054148

28. Install drive gear (9) to the drive flange.

29. Install bolts (8). Tighten bolts (8) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 23	g01059821

30. Raise the temperature of inner bearing (7). Install inner bearing (7) to bearing carrier (1).

    Note: Lubricate bearing (7) with clean transmission oil.

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    Illustration 24	g01059823

31. Install retaining ring (6) to bearing carrier (1).

32. Raise the temperature of ring carrier (5). Install ring carrier (5) to bearing carrier (1).
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    Illustration 25	g01054143

33. Install seal ring (4) to ring carrier (5).

34. Install O-ring seal (3) to bearing carrier (1).
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    Illustration 26	g01059825

35. Check the clearance between the impeller hub and the bearing carrier. The clearance, dimension must be 0.20 ± 0.05 mm (0.008 ± 0.002 inch).
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    Illustration 27	g01059824

36. Install bearing carrier (1) to carrier assembly (20).

37. Install retaining ring (2) to carrier assembly (20).

End By:

1. Connect the torque converter to the updrive gears. Refer to Disassembly and Assembly, "Updrive Gears - Assemble".