R1700G Load Haul Dump Power Train Caterpillar

Updrive Gears - Assemble

Usage:

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7574	Link Bracket	2
B		Loctite 7649	1
C		Loctite 271	1
D		!/2 inch - 13 NC x 6 inch Guide Bolt	1
E		3/8 inch - 16 NC x 2 1/2 inch Guide Bolt	1
F	1P-0520	Driver Group	1
G	3H-1930	Bolt	1
H	1U-8846	Gasket Sealant	1

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 always.

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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NOTICE

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

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NOTICE

Failure to properly assemble parts or failure to follow established procedures can lead to damage of the parts and assembly. To avoid damage to parts, always identify and mark the parts so that they can be installed in the same location. Ensure that gear surfaces align. Never force parts during assembly.

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Illustration 1	g01230717

Install retaining ring (89) to bearing (88).
Install bearing retainer (87) to pump drive gear (85).
Raise the temperature of bearing (88). Install bearing (88) on pump drive gear (85).
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Illustration 2 g01230716
Install retaining ring (86) to pump drive gear (85).
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Illustration 3 g01230732
Install pump drive gear (85).
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Illustration 4 g01230715
Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (84) prior to installation.
Install six bolts (84). Tighten bolts (84) evenly to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Note: Ensure that the bearing is seated in the housing.
Install pump drive shaft (83) to gear assembly (85).
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Illustration 5 g01230714
Install retaining ring (82) in transfer gear (77).
Install spacer (81) to transfer gear (77). Ensure that the chamfered face of spacer (81) is facing upwards.
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Illustration 6 g01231118

Note: Bearing cups and bearing cones in idler gear (77) are a matched set. Mark bearing cups and bearing cones to ensure that they are installed as a matched set.
Lower the temperature of bearing cup (80). Use Tooling (F) to install bearing cup (80) to transfer gear (77).
Repeat Step 11 to install the bearing cup in the other side of transfer gear (77).
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Illustration 7 g01231119

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Illustration 8 g01230711
Install two bearing cones (78) and spacer (79) to transfer gear (77).
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Illustration 9 g01230710
Install O-ring seal (76) on shaft (75).
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Illustration 10 g01231125

Note: Tooling (D) must be modified to be used as a guide bolt. Position Tooling (D) in a suitable vise. Remove the head of the bolt to use Tooling (D) as a guide bolt.
Install Tooling (D) to shaft (75).
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Illustration 11 g01230708
Install transfer gear (77).
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Illustration 12 g01230707
Install shaft assembly (75) through transfer gear (77). Remove Tooling (D).
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Illustration 13 g01230706
Apply Tooling (B) and then apply Tooling (C) to the threads of bolt (74) prior to assembly. Install bolt (74) and the washer. Tighten bolt (74) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
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Illustration 14 g01230705
Lower the temperature of bearing cup (72). Use Tooling (F) to install bearing cup (72) to adapter (70).
Install O-ring seal (73).
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Illustration 15 g01230702
Install adapter (70).
Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (71) prior to installation. Install 12 bolts (71). Tighten bolts (71) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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Illustration 16 g01230379
Raise the temperature of bearing cone (69). Install bearing cone (69) on gear assembly (68).
Repeat Step 23 to install the bearing cone on the other side of gear assembly (68).
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Illustration 17 g01231162

Note: Tooling (E) must be modified to be used as a guide bolt. Position Tooling (E) in a suitable vise. Remove the head of the bolt to use Tooling (E) as a guide bolt.
Install gear assembly (68) and Tooling (E) to the updrive housing.
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Illustration 18 g01231455
Lower the temperature of bearing cup (66). Use Tooling (F) to install bearing cup (66) in adapter (65).
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Illustration 19 g01231458
Install full shim pack (90).
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Illustration 20 g01231469
Install adapter (65).
Note: Do not install the O-ring seal on the adapter at this time.
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Illustration 21 g01231472
Install 12 bolts (64). Tighten bolts (64) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Rotate the gear assembly at least three revolutions to seat the bearings.
Measure the end play of the gear assembly. Add or subtract shims (90) to obtain an end play measurement of 0.15 ± 0.05 mm (0.006 ± 0.002 inch).
When the correct shim thickness has been obtained remove adapter (65).
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Illustration 22 g01231474
Install O-ring seal (67) to adapter (65).
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Illustration 23 g01264825
Install shims (90) (not shown), the amount determined in Step 31 and adapter (65).
Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (64) prior to installation. Install 12 bolts (64). Tighten bolts (64) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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Illustration 24 g01230374

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Illustration 25 g01230373
Lower the temperature of bearing cup (59). Use Tooling (F) to install bearing cup (59).
Note: Ensure orifice plugs (58), (60) and (61) are installed and free of foreign material.
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Illustration 26 g01230363
Raise the temperature of bearing cone (47). Install bearing cone (47) to transfer gear (46).
Repeat Step 37 for the bearing on the other side of transfer gear (46).
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Illustration 27 g01231492
Install transfer gear (46).
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Illustration 28 g01231495
Install Tooling (E) and shim pack (91).
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Illustration 29 g01231493
Lower the temperature of bearing cup (35). Use Tooling (F) to install bearing cup (35) in cage assembly (32).
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Illustration 30 g01231498
Install cage assembly (32).
Note: Do not install the O-ring seals or the lip seal to the cage assembly at this time.
Install four bolts (33). Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Rotate the transfer gear at least three revolutions to seat the bearings.
Measure the end play of the transfer gear. Add or subtract shims (91) to obtain an end play measurement of 0.15 ± 0.05 mm (0.006 ± 0.002 inch).
When the correct shim thickness has been obtained remove cage assembly (32), shim pack (91) and transfer gear (46).
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Illustration 31 g01230375
If removed install locating dowels (62) in the bearing carrier.
Install O-ring seal (63).
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Illustration 32 g01230371
Install Tooling (A) and a suitable lifting device to the torque converter and updrive gears housing. The weight of the torque converter and updrive gears housing is approximately 228 kg (502 lb).
Install the torque converter and updrive gears housing to the torque converter.
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Illustration 33 g01230372
Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (57) prior to installation. Install eight bolts (57). Tighten bolts (57) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
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Illustration 34 g01230370
Lower the temperature of bearing cup (56). Use Tooling (F) to install bearing cup (56) to bearing cage (54).
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Illustration 35 g01230369
Install bearing cage (54).
Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (55) prior to installation. Install six bolts (55). Tighten bolts (55) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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Illustration 36 g01230366
Raise the temperature of bearing cone (52). Install bearing cone (52) to transfer gear (49).
Repeat Step 55 for the bearing on the other side of transfer gear (49).
Install retaining ring (51) in transfer gear (49).
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Illustration 37 g01231510
Install transfer gear (49). Ensure that the splined end of the gear is facing towards the housing.
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Illustration 38 g01231511
Lower the temperature of bearing cup (42). Use Tooling (F) to install bearing cup (42) in cage assembly (40).
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Illustration 39 g01231513
Install Tooling (E) and shim pack (92).
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Illustration 40 g01232004
Install a suitable plate (93) to transfer gear (49).
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Illustration 41 g01232006
Install cage assembly (40).
Note: Do not install the O-ring seals to the cage assembly at this time.
Install six bolts (41). Tighten bolts (41) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Rotate the transfer gear at least three revolutions to seat the bearings.
Measure the end play of the transfer gear. Add or subtract shims (92) to obtain an end play measurement of 0.15 ± 0.05 mm (0.006 ± 0.002 inch).
When the correct shim thickness has been obtained remove cage assembly (40), shim pack (92), plate (93), and transfer gear (49).
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Illustration 42 g06246711
Check that orifice plug (53) is clean and free of foreign material.
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Illustration 43 g06247223
Install output shaft (50) to the torque converter.
Note: Orientate the output shaft to ensure that the orifice plug is installed first. Refer to Illustration 42.
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Illustration 44 g01230365
Install transfer gear (49) to output shaft (50).
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Illustration 45 g01230364
Install output shaft (47).
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Illustration 46 g01230362
Install transfer gear (46).
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Illustration 47 g01232012

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Illustration 48 g01232013
Install Tooling (H) through transfer gear (46) into output shaft (47). Use Tooling (H) to pull up output shaft (47) through transfer gear (46).
Install retaining ring (45) to output shaft (47).
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Illustration 49 g01259615
Install two O-ring seals (44) to cage assembly (40).
Note: Ensure that orifice plug (43) is installed and free of foreign material.
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Illustration 50 g01264826
Install shims (92) (not shown), the amount that were determined in Step 65 and cage assembly (40).
Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (41) prior to assembly. Install six bolts (41). Tighten bolts (41) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Install the O-ring seal to plug (39). Install plug (39).
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Illustration 51 g01230358
Install spacer (38).
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Illustration 52 g01232022
Install two O-ring seals (37) to cage assembly (32).
Note: Ensure that orifice plug (36) is installed and free of foreign material.
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Illustration 53 g01264837
Use Tooling (F) to install lip seal (34) to cage assembly (32).
Install shims (91) (not shown), the amount that were determined in Step 45 and cage assembly (32).
Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (33) prior to installation. Install six bolts (33). Tighten bolts (33) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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Illustration 54 g01230355
Install yoke (30). Install O-ring seal (31).
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Illustration 55 g01230348
Apply Tooling (B) and then apply Tooling (C) to the threads of bolt (28) prior to installation. Install retainer (29) and bolt (28). Tighten bolt (28) to a torque of 135 ± 15 N·m (100 ± 11 lb ft).
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Illustration 56 g01230347
Install two O-ring seals (27) to cage assembly (25).
Note: Ensure that orifice plug (26) is installed and free of foreign material.
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Illustration 57 g01230345
Install cage assembly (25). Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (24) prior to assembly. Install eight bolts (24). Tighten bolts (24) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Apply Tooling (H) to plug (23) prior to installation. Install plug (23) to cage assembly (25).
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Illustration 58 g01230367
Install two O-ring seals (22) to cage assembly (18).
Note: Ensure that orifice plug (21) is installed and free of foreign material.
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Illustration 59 g01230029
Install cage assembly (18). Apply Tooling (B) and then apply Tooling (C) to the threads of bolts (20) prior to installation. Install six bolts (20). Tighten bolts (20) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Install the O-ring seal to plug (19).
Install plug (19) to cage assembly (18).
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Illustration 60 g01230026
Apply Tooling (H) to plug (17) prior to installation. Install plug (17).
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Illustration 61 g01230024
Install O-ring seals (15) and (16) to gear pump (13).
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Illustration 62 g01230023
Install gear pump (13).
Install seven bolts (14).
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Illustration 63 g01230022
Install plug (12) and the washer.
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Illustration 64 g01230021
Install elbow (11).
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Illustration 65 g01230020
Install O-ring seal (10) on adapter (8).
Note: Ensure that orifice plug (9) is free of foreign material.
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Illustration 66 g01230019
Install adapter (8) and two bolts (7).
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Illustration 67 g01230016
Using a suitable lifting device, position the torque converter and updrive transfer gears on wood blocks in an upright position. The weight of the torque converter and updrive transfer gears is approximately 519 kg (1144 lb).
Install adapter (5) and four bolts (6).
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Illustration 68 g01230015
Install pump support bracket (4). Install four bolts (3).
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Illustration 69 g01233056
Install O-ring seals (94) and (95) to torque converter outlet relief valve (2).
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Illustration 70 g01230014
Install torque converter outlet relief valve (2). Install three bolts (1).

End By:

Connect the torque converter and updrive gears to the engine. Refer to Disassembly and Assembly, "Engine to Torque Converter and Updrive gears - Connect".