785D OEM Off-Highway Truck Power Train Caterpillar

Axle Housing - Install

Usage:

785D DMC

Installation Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	504-9790	Lift Gp (60Hz)⁽¹⁾	4
	OR
	504-9792	Lift Gp (50Hz)⁽²⁾	4
B	1U-9200	Lever Puller Hoist	1
C	189-0863	Shackle As	2
D	208-8784	Plate	2
E	8S-7615	Pin As	2
	283-1495	Stand Assembly	2
	8S-7611	Handle As	2
F	-	Anti-Seize Compound	-

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⁽¹⁾	High-Voltage (480V) Low-Voltage (240V)
⁽²⁾	High-Voltage (400V) Low-Voltage (200V)

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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, spacers, 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.

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Illustration 1	g01761605

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Illustration 2	g01761615

Use Tooling (B), Tooling (C), Tooling (D), and a suitable lifting device to position rear axle housing (33) and transmission (34). The weight of rear axle housing (33) and transmission (34) is approximately 16783 kg (37000 lb).
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Illustration 3 g06273516
Position Tooling (A) to support rear axle housing (33). Refer to Tool Operating Manual, NEHS1303, "Lift Group (Stand - 25 Ton)" for more information.
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Illustration 4 g01762495
Install bolts (43).
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Illustration 5 g01762453
Install bolts (42).
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Illustration 6 g06273577
Remove Tooling (E) from axle housing support (41). Repeat this step for the opposite side.
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Illustration 7 g01762433

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Illustration 8 g01762256
Install tube assembly (38). Install clips (40). Connect hose (39). Connect tube assembly (38).
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Illustration 9 g01762136

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Illustration 10 g01762196
Install tube assembly (35). Install clips (37). Connect hose (36). Connect tube assembly (35).
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Illustration 11 g01761558

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Illustration 12 g01761601
Use a suitable lifting device to position lateral control rod (31). The weight of lateral control rod (31) is approximately 113 kg (250 lb). Apply Tooling (F) onto pin assembly (32) and the bore that is in the rear axle housing.
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Illustration 13 g01761514

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Illustration 14 g01761598
Install retainer plates (30). Install bolt (29).
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Illustration 15 g01761516
Position lubrication group (28). Install bolts (27). Connect hose assembly (26).
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Illustration 16 g01761014
Connect grease hose assembly (25).
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Illustration 17 g01760974
Connect grease hose assembly (24).
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Illustration 18 g01760934
Install pin assembly (23).
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Illustration 19 g01760913
Install plate (22). Install bolts (21).
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Illustration 20 g01760877
Connect grease hose assembly (20).
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Illustration 21 g01760799
Connect grease hose assembly (19).
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Illustration 22 g01760533
Install guard assembly (18).
Repeat Step 13 through Step 17 for the remaining suspension cylinder.
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Illustration 23 g01760358
Install clips (17).
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Illustration 24 g01760262
Install clips (16).
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Illustration 25 g01760258
Install clips (15).
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Illustration 26 g01760254
Connect hose assembly (14).
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Illustration 27 g01760093
Connect hose assemblies (13).
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Illustration 28 g01760085
Connect hose assemblies (12).
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Illustration 29 g01760076
Connect hose assemblies (11).
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Illustration 30 g01760034
Connect hose assemblies (10). Connect harness assembly (9).
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Illustration 31 g01759894
Connect hose assemblies (8).
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Illustration 32 g01759876
Connect harness assemblies (7) and install the connecting hardware.
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Illustration 33 g01759874
Install step (6).
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Illustration 34 g01759213
Connect hose assembly (5).
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Illustration 35 g01759173
Connect hose assemblies (4).
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Illustration 36 g01759794

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Illustration 37 g01759838
Use a suitable lifting device to position drive shaft (2). The weight of drive shaft (2) is approximately 68 kg (150 lb). Extend drive shaft (2) and install bolts (3). Tighten bolts (3) to a torque of 550 ± 20 N·m (406 ± 15 lb ft). Remove the suitable blocking.
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Illustration 38 g01759155
Install drive shaft guard (1).
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Illustration 39 g06273514
Remove Tooling (A).
Fill the torque converter and the transmission. Refer to Operation and Maintenance Manual, "Torque Converter and Transmission Oil - Change".
Fill the hoist/brake hydraulic tank. Refer to Operation and Maintenance Manual, "Hoist and Brake Tank Oil - Change".
Fill the differential and final drive. Refer to Operation and Maintenance Manual, "Differential and Final Drive Oil - Change".