R2900G Load Haul Dump Power Train Caterpillar

Installation Procedure

Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 1	g02742377

1. Install O-ring seal (12).
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   Illustration 2	g02742396

2. Install Tooling (D) to the axle housing.

   Note: Tooling (D) must be modified in order to be used as a guide bolt. Position Tooling (D) in a suitable vice. Remove the head of the bolt in order to use Tooling (D) as a guide bolt.

3. Install Tooling (C) and a suitable lifting device to the differential and bevel gear assembly. The weight of the rear differential and bevel gear assembly is approximately 415 kg (915 lb). Install the differential and bevel gear assembly to the axle housing.

4. Remove Tooling (D) from the axle housing.
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   Illustration 3	g02742416

5. Install four special bolts (11) in order to align the differential and bevel gear assembly to the axle housing.

   Note: Bolts (11) are longer.

6. Apply Tooling (E) to 20 bolts (10).

7. Install 20 bolts (10). Tighten 20 bolts (10) to a torque of 475 ± 60 N·m (350 ± 44 lb ft).

8. Remove four special bolts (11). Apply Tooling (E) to four special bolts (11).

9. Install four special bolts (11). Tighten four special bolts (11) to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
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   Illustration 4	g01088537

10. Attach Tooling (B) and a suitable lifting device to front trunnion support (9). The weight of front trunnion support (9) is approximately 87 kg (192 lb). Install front trunnion support (9) to the pinion housing.
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    Illustration 5	g01088536

11. Install yoke assembly (8).

12. Install manifold (7) to the rear axle housing.

13. Install clip (6).
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    Illustration 6	g01088136
    Typical example

14. Install O-ring seal (4) to pin (5).

15. Use Tooling (A) in order to install pin (5) to the axle housing.
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    Illustration 7	g01088544
    Typical example

16. Install cover (3) and bolts (1). Tighten bolts (1) evenly to a torque of 47 N·m (35 lb ft).

17. Use a feeler gauge to measure the gap between the axle housing and cover (3).

18. Subtract 0.05 ± 0.03 mm (0.002 ± 0.001 inch) from the measurement found in Step 17. This is the thickness of shims that are required.

19. Remove bolts (1) and cover (3).
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    Illustration 8	g01088133

20. Install shims (2), cover (3) and bolts (1). Tighten bolts (1) to a torque of 100 ± 15 N·m (75 ± 10 lb ft).

End By:

1. Install the axle shafts. Refer to Disassembly and Assembly, "Axle Shaft - Install".

2. Install the rear axle assembly. Refer to Disassembly and Assembly, "Oscillating Axle (Rear) - Install".