785D OEM Off-Highway Truck Power Train Caterpillar

Transmission Planetary - Assemble

Usage:

785D DMC

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	439-3939	Link Bracket	2
B	439-3938	Link Bracket	2
C	1P-2420	Repair Stand for Transmission	1
D	1P-0520	Driver Group	1
E	2D-1201	Eyebolt	1
F	-	Loctite 5009	-
G	435-1290	Alignment Fixture Assembly	1

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

Note: Inspect the O-ring seals, the seals, and the gaskets. Replace the O-ring seals, the seals, and the gaskets that are worn or damaged.

Note: Lubricate the O-ring seals lightly with the lubricant that is being sealed.

Note: Lubricate all bores and the bearings lightly with the lubricant that is being sealed.

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Illustration 1	g01627760

Install O-ring seals (188) onto tube assembly (187).
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Illustration 2 g06196520
Install Tooling (G) and tube assembly (187).
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Illustration 3 g01627754
Raise the temperature of bearing race (186). Install bearing race (186) and seal ring (185) into clutch housing (180).
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Illustration 4 g01627739
Lower the temperature of bearing race (182). Use Tooling (D) to install bearing race (182) onto cage (181).
Install O-ring seals (183) and seal ring (184).
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Illustration 5 g01627738
Use Tooling (D) to install cage (181) onto clutch housing (180).
Note: Align cage (181) and clutch housing (180) with the marks that were created in the disassembly procedure.
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Illustration 6 g01627735
Use Tooling (B) and a suitable lifting device to install clutch housing (180). The weight of clutch housing (180) is approximately 57 kg (125 lb).
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Illustration 7 g01627734
Install seal ring (179) and seal ring (178) onto clutch piston (177).
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Illustration 8 g01627521
Install clutch piston (177). Install springs (176).
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Illustration 9 g01627519
Install seal ring (175) onto balance piston (174).
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Illustration 10 g01627517

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install balance piston (174). Install bolts (173).
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Illustration 11 g01627509
Install hub (172).
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Illustration 12 g01627504
Install discs (170) and plates (171).
Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to install the discs and the plates in this order. Install a friction disc last.
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Illustration 13 g01627502
Use two people to install plate (169).
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Illustration 14 g01627501
Install sun gear (168) and retaining ring (167).
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Illustration 15 g01627496
Use Tooling (B) and a suitable lifting device to install housing (166). The weight of housing (166) is approximately 45 kg (100 lb).
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Illustration 16 g01627489
Use two people to install carrier housing (165) onto shaft (158). Install retaining ring (164).
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Illustration 17 g01627482

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Illustration 18 g01627478
Install shaft (162), thrust discs (163), gear (160), and bearings (161) into planetary carrier (157). Repeat this procedure for the remaining gears.
Install pins (159).
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Illustration 19 g01627470
Use Tooling (E) and a suitable lifting device to install planetary carrier (157) and shaft (158). The weight of planetary carrier (157) and shaft (158) is approximately 113 kg (250 lb).
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Illustration 20 g01627459
Install hub (156). Install retainers (155) and bolts (154).
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Illustration 21 g01627453
Install plates (153) and discs (152).
Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to install the discs and the plates in this order. Install a friction disc last.
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Illustration 22 g01627448
Install O-ring seal (151) onto tube (146).
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Illustration 23 g01627443
Install spring pin (150) and O-ring seal (149) onto plug (147).
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Illustration 24 g01627432
Install tube (146). Install flange (148) and plug (147).
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Illustration 25 g01627431
Install O-ring seal (145) onto tube (146).
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Illustration 26 g01627413
Install balls (144) onto manifold (117).
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Illustration 27 g01627411

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install cap (139), spring (140), washer (144), valve (141), body (142), and O-ring seal (143).
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Illustration 28 g01627407
Install plugs (138) and relief valve (137). Tighten relief valve (137) to a torque of 41 ± 7 N·m (30 ± 5 lb ft).
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Illustration 29 g01627401
Install dowels (136) onto ring carrier (135).
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Illustration 30 g01295199
Use a suitable lifting device to install manifold (117) onto ring carrier (135). The weight of manifold (117) is approximately 73 kg (160 lb). Install bolts (134).
Install seal rings (133).
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Illustration 31 g01627387
Install seal rings (132).
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Illustration 32 g01627385
Lower the temperature of bearing (131). Use Tooling (D) to install bearing (131). Install seal ring (130).
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Illustration 33 g01627383
Install seal ring (129).
Use Tooling (B) and a suitable lifting device to install clutch housing (128). The weight of clutch housing (128) is approximately 50 kg (110 lb).
Install retaining ring (127).
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Illustration 34 g01627381
Install seal ring (126) and springs (125) onto clutch piston (121).
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Illustration 35 g01627380
Install seal ring (124) onto balance piston (122).
Use Tooling (D) to install bearing sleeve (123) onto balance piston (122).
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Illustration 36 g01627379
Install balance piston (122) onto clutch piston (121).
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Illustration 37 g01627378

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Use two people to install clutch piston (121) and balance piston (122). The weight of clutch piston (121) and balance piston (122) is approximately 34 kg (75 lb).
Install bolts (120).
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Illustration 38 g01627371

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Illustration 39 g01627375
Use Tooling (B) and a suitable lifting device to install manifold (117) and clutch (118). The weight of manifold (117) and clutch (118) is approximately 136 kg (300 lb).
Install bolts (119). Tighten bolts (119) to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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Illustration 40 g01627367
Connect tube assembly (116).
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Illustration 41 g01627365
Install seal rings (115) and springs (114) onto clutch piston (108).
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Illustration 42 g06128992
Install seal rings (113) and O-ring seal (189) onto balance piston (109).
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Illustration 43 g01627363

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install balance piston (109) onto clutch piston (108).
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Illustration 44 g01627360
Use Tooling (D) to install bearing (112).
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Illustration 45 g01627358
Install retaining ring (111).
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Illustration 46 g01627346
Use two people to install clutch piston (108) and balance piston (109) into clutch housing (107). The weight of clutch piston (108) and balance piston (109) is approximately 34 kg (75 lb).
Note: Align clutch piston (108), balance piston (109), and clutch housing (107) with the marks that were created in the disassembly procedure.
Install bolts (110).
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Illustration 47 g01627340
Use Tooling (B) and a suitable lifting device to install clutch housing (107), clutch piston (108), and balance piston (109). The weight of clutch housing (107), clutch piston (108), and balance piston (109) is approximately 77 kg (170 lb).
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Illustration 48 g01627335
Install retaining ring (106) and retaining ring (105).
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Illustration 49 g01627329
Install hub (101) onto sun gear (102). Install retaining ring (104).
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Illustration 50 g01627325
Install seal rings (103).
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Illustration 51 g01627324
Use Tooling (B) and a suitable lifting device to install hub (101) and sun gear (102). The weight of hub (101) and sun gear (102) is approximately 36 kg (80 lb).
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Illustration 52 g01627320
Install plates (100) and discs (99).
Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to install the discs and the plates in this order. Install a friction disc last.
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Illustration 53 g01627317
Install shaft (95), thrust washers (96), gear (97), and bearings (98). Repeat this procedure for the remaining gears.
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Illustration 54 g01627314

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Illustration 55 g06257773
Install four spring pins (94). One of the spring pins should be installed in the bottom of the carrier housing.
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Illustration 56 g01627311
Use Tooling (D) and a suitable press to install bearing retainer (92) onto bearing (93).
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Illustration 57 g01627309
Use Tooling (D) to install bearing (93) and bearing retainer (92).
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Illustration 58 g01627307
Install retaining ring (90) and O-ring seal (91) onto bearing retainer (92).
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Illustration 59 g01627298
Use Tooling (B) and a suitable lifting device to install planetary carrier (89). The weight of planetary carrier (89) is approximately 68 kg (150 lb).
Install bolts (88).
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Illustration 60 g01627297
Use Tooling (B) and a suitable lifting device to install clutch housing (87). The weight of clutch housing (87) is approximately 118 kg (260 lb).
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Illustration 61 g01627295
Use two people to install ring gear (86).
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Illustration 62 g01627291
Install seal rings (85) onto clutch piston (84).
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Illustration 63 g01627288
Install clutch piston (84).
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Illustration 64 g01627285
Install plates (83) and discs (82).
Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to install the discs and the plates in this order. Install a friction disc last.
Install pins (81) and springs (80).
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Illustration 65 g01627282
Use a suitable lifting device to install ring gear (79) onto clutch housing (78). The weight of ring gear (79) is approximately 50 kg (110 lb).
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Illustration 66 g01627278

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Use Tooling (B) and a suitable lifting device to install clutch housing (78) and ring gear (79). The weight of clutch housing (78) and ring gear (79) is approximately 113 kg (250 lb).
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Illustration 67 g01627209
Install retainers (77) and bolts (76).
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Illustration 68 g01627205
Install sun gear (75). Install retaining ring (74).
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Illustration 69 g01627201
Install shaft (70), thrust discs (73), gear (72), and bearings (71). Repeat this procedure for the remaining gears.
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Illustration 70 g01627199
Install spring pins (69).
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Illustration 71 g01627198
Use Tooling (B) and a suitable lifting device to install planetary carrier (68). The weight of planetary carrier (68) is approximately 125 kg (275 lb).
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Illustration 72 g01627196
Install spacer (67).
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Illustration 73 g01627195
Install sun gear (65) onto hub (64). Install retaining ring (66).
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Illustration 74 g01627192
Use two people to install hub (64) and sun gear (65). The weight of hub (64) and sun gear (65) is approximately 27 kg (60 lb).
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Illustration 75 g01627188
Install retaining ring (63).
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Illustration 76 g01627187
Install seal rings (62) onto clutch piston (61).
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Illustration 77 g01627185
Use two people to install clutch piston (61).
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Illustration 78 g01627086
Install plates (60) and discs (59).
Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to install the discs and the plates in this order. Install a friction disc last.
Install pins (58) and springs (57).
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Illustration 79 g01627085

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Use Tooling (A) and a suitable lifting device to install clutch housing (56). The weight of clutch housing (56) is approximately 68 kg (150 lb).
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Illustration 80 g01627084
Install seal rings (55) onto clutch piston (54).
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Illustration 81 g01627082
Use two people to install clutch piston (54).
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Illustration 82 g01627077
Use Tooling (B) and a suitable lifting device to install ring gear (53). The weight of ring gear (53) is approximately 36 kg (80 lb).
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Illustration 83 g01627075
Install shaft (49), thrust discs (52), gear (51), and bearings (50). Repeat this procedure for the remaining gears.
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Illustration 84 g01627074
Install spring pins (48).
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Illustration 85 g01627073
Use Tooling (B) and a suitable lifting device to install planetary carrier (47). The weight of planetary carrier (47) is approximately 113 kg (250 lb). Install O-ring seal (46).
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Illustration 86 g01627069
Install oil slinger (45) and ring (44). Install bolts (43).
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Illustration 87 g01627066
Install plates (42) and discs (41).
Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to install the discs and the plates in this order. Install a friction disc last.
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Illustration 88 g01668302
Install pins (40) and pins (39). Install springs (38) and springs (37).
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Illustration 89 g03733328

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Improper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
Install thrust buttons (35A). Use Tooling (B) to install end housing (36). The weight of end housing (36) is approximately 45 kg (100 lb).
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Illustration 90 g01627061
Install baffle (35). Apply Tooling (F) onto the bolt face of baffle (35). Install bolts (34). Install bearing (33). Install retaining ring (32).
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Illustration 91 g01627864
Raise the temperature of drive adapter (31). Install drive adapter (31). Install bolts (30).
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Illustration 92 g01627044

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Illustration 93 g01627054

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Personal injury or death can occur from heavy components falling during removal or installation.
Properly support the component with a suitable lifting device during removal or installation.
Use Tooling (A) and a suitable lifting device to install transmission case (29). The weight of transmission case (29) is approximately 318 kg (700 lb).
Install bolts (28).
Install bolts (27). Tighten bolts (27) to a torque of 410 ± 50 N·m (302 ± 37 lb ft).
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Illustration 94 g01627039
Install magnets (26) onto tube assembly (25). Repeat for the remaining screen tube assembly (25).
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Illustration 95 g01627036
Install tube assembly (25) onto suction screen (24). Repeat this step for the remaining suction screen (24).
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Illustration 96 g01627034
Install tube assemblies (25) and suction screens (24).
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Illustration 97 g01627032
Install wave washers (23). Install O-ring seals (22).
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Illustration 98 g01627026
Install covers (21). Install nuts (20).
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Illustration 99 g01627014
Install O-ring seals (19).
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Illustration 100 g01627011
Install magnetic screen assembly (18).
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Illustration 101 g01627007

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Illustration 102 g01627867
Use Tooling (B) and a suitable lifting device to remove transmission and transfer gears (1) from Tooling (C). The weight of transmission and transfer gears (1) is approximately 2132 kg (4700 lb).
Position transmission and transfer gears (1) onto a suitable repair stand.
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Illustration 103 g01627006
Use Tooling (A) and a suitable lifting device to install control valve (17). The weight of control valve (17) is approximately 64 kg (141 lb).
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Illustration 104 g01627004
Install bolts (16). Tighten bolts (16) to a torque of 48 ± 4 N·m (35 ± 3 lb ft).
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Illustration 105 g01627003
Install O-ring seals (15). Install sleeve (14). Install O-ring seal (13). Repeat this step for the remaining flange (12).
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Illustration 106 g01627002
Install flanges (12).
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Illustration 107 g01626999
Install coupling assembly (11). Install retaining ring (10).
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Illustration 108 g01626998
Install O-ring seals (9) onto sleeve (7). Repeat this step for the remaining sleeves (7).
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Illustration 109 g01626996
Install O-ring seals (8). Install sleeves (7).
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Illustration 110 g01626994
Install manifold assembly (6). Install bolts (5). Tighten bolts (5) to a torque of 48 ± 4 N·m (35 ± 3 lb ft).
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Illustration 111 g01626992
Install a new gasket and cover (4). Install a new gasket and cover (3).
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Illustration 112 g01626991
Install guard (2).