785G Off-Highway Truck Power Train Caterpillar

Torque Converter - Assemble

Usage:

785G RTL

Disassembly Procedure

Show/hide table

Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	439-3940	Link Bracket	2
B	439-3939	Link Bracket	1
C	1U-9200	Lever Puller Hoist	1
E	1P-2420	Transmission Repair Stand	1
F	0S-1614	Bolt	2
F	5P-0537	Hard Washer	2
H	1P-0520	Driver Group	1
K	395-1100	Lifting Eye Assembly	1

Start By:

Assemble the torque converter.

Show/hide table




Illustration 1	g06291045

Use a suitable press to install ball bearing (101).
Show/hide table

Illustration 2 g06291059
Use Tooling (K) and a suitable lifting device to install output shaft (100) and the ball bearing . The weight of output shaft (100) and the ball bearing is approximately 26 kg (57 lb).
Show/hide table

Illustration 3 g06290603
Install ring carrier (99), ring seal (98), and O-ring seal (97).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 4 g06290568
Install O-ring seal (95), seal wear sleeve (93), lip seal (94), plug assembly (92), and plug assemblies (96).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 5 g06291114
Install fluid distributor (91), and bolts (90). Tighten bolts (90) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Attach a suitable lifting device to lift and reposition the output shaft, stator carrier, and fluid distributor onto Tooling (E). The weight of the components is approximately 67 kg (148 lb).
Show/hide table

Illustration 6 g06290112
Raise the temperature of bearing (89). Install bearing (89), snap ring (88), and seal rings (87).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 7 g06290101
Install freewheel race (86), split washers (85), and bolts (84). Tighten bolts (84) to a torque of 30 ± 5 N·m (266 ± 44 lb in).
Show/hide table

Illustration 8 g06290093
Install pump drive gear (83) and bolts (82). Tighten bolts (82) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Show/hide table

Illustration 9 g06290071
Attach Tooling (A) and a suitable lifting device to impeller housing (81). The weight of impeller housing (81) is approximately 46 kg (102 lb). Rotate impeller housing (81) and install.
Show/hide table

Illustration 10 g06289651
Install hub impeller (80) and bolts (79). Tighten bolts (79) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
Show/hide table

Illustration 11 g06289647
Install thrust race pins (78).
Show/hide table

Illustration 12 g06289605
Install thrust race (77), thrust bearing (75), and sleeve (76).
Show/hide table

Illustration 13 g06289597

Install freewheel cam (72), side plate (73), and retaining ring (74). Install stator assembly (66).

Show/hide table




Illustration 14	g06289589

Show/hide table

Personal injury can result from being struck by parts propelled by a released spring force.
Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to release the spring force.

Install roller cage (69), freewheel rollers (70), and springs (71).
Show/hide table

Illustration 15 g06289531
Install top retaining ring (67) and side plate (68) onto stator (66).
Show/hide table

Illustration 16 g06289479
Install stator assembly (66).
Note: The rollers inside stator assembly (66) are free to move when the stator assembly is installed.
Show/hide table

Illustration 17 g06289203
Install thrust bearing (65), thrust race (64), sleeve (63), and snap ring (62).
Show/hide table

Illustration 18 g06289094
Install ring seal (60) onto seal carrier (59). Install seal carrier (59) and wear sleeve (61) onto bearing (58).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 19 g06291349
Use Tooling (H) to install bearing (58).
Show/hide table

Illustration 20 g06288628
Install seal ring (56) and O-ring seal (57).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 21 g06288585
Install seal ring (54) and O-ring seal (55) onto lockup clutch piston (53). Install lockup clutch piston (53) and hub (52).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 22 g06288901
Install Tooling (F).
Show/hide table

Illustration 23 g06288241
Install friction discs (50), and clutch plates (51).
Show/hide table

Illustration 24 g06288237
Install backing plate (49) and retaining ring (48).
Show/hide table

Illustration 25 g06288236
Install turbine (47) and hub assembly (46). Tighten bolts to a torque of 80 ± 10 N·m (60 ± 7 lb ft).
Show/hide table

Illustration 26 g06291363
Rotate housing assembly (45). Use Tooling (A) and a suitable lifting device to install housing assembly (45). The weight of housing assembly (45) is approximately 140 kg (309 lb).
Install bolts (44). Tighten bolts (44) to a torque of 240 ± 25 N·m (177 ± 18 lb ft).
Show/hide table

Illustration 27 g06287808
Remove Tooling (F).
Show/hide table

Illustration 28 g06287802
Install washer (43), retainer (42), and bolts (41). Tighten bolts (41) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
Show/hide table

Illustration 29 g06287564
Use Tooling (A) and a suitable lifting device to rotate torque converter (38) and place on suitable cribbing in the position that is shown. The weight of torque converter (38) is approximately 324 kg (715 lb).
Install O-ring seal (39) and O-ring seal (40).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 30 g06287464
Attach Tooling (A) and a suitable lifting device onto torque converter housing (36). The weight of torque converter housing (36) is approximately 670 kg (1477 lb). Lower torque converter housing (36) onto torque converter (38).
Show/hide table

Illustration 31 g06287553
Install bolts (37).
Show/hide table

Illustration 32 g06287294
Install yoke (35) and O-ring seal (34).
Show/hide table

Illustration 33 g06286989
Install retainer (33) and bolt (32). Tighten bolt (32) to a torque of 240 ± 25 N·m (177 ± 18 lb ft).
Show/hide table

Illustration 34 g06286972
Install gasket (31) and tube assembly (30).
Show/hide table

Illustration 35 g06286963
Install valve (29).
Show/hide table

Illustration 36 g06287339
Install gasket (28) and cover (27).
Show/hide table

Illustration 37 g06287358
Install level sensor (26). Tighten level sensor (26) to a torque of 22 ± 3 N·m (195 ± 275 lb in).
Show/hide table

Illustration 38 g06287355
Install plug (24) and cover plate (25).
Show/hide table

Illustration 39 g06286954
Install plate (23), spacer (22), and floats (21).
Note: Spherical floats to be installed in oil sight gauge cavity.
Show/hide table

Illustration 40 g06286951
Install glass (18) into grommet (19). Install gasket (17) and O-ring seal (20).
Show/hide table

Illustration 41 g06286937
Install cover (15) and drain assembly (16).
Show/hide table

Illustration 42 g06286921
Install screen (14) and O-ring seal (13).
Note: Lubricate the O-rings and seal with the lubricant that is being used.
Show/hide table

Illustration 43 g06286917
Install cover (11), bolts (10), and elbow assembly (12).
Show/hide table

Illustration 44 g06286893
Install O-ring seal (7), O-ring seal (8), and O-ring seal (9) onto torque converter inlet relief valve (6).
Show/hide table

Illustration 45 g06286881
Install torque converter inlet relief valve (6) and bolts (5).
Show/hide table

Illustration 46 g02001995
Use Tooling (A), Tooling (B), Tooling (C), and a suitable lifting device to position torque converter assembly (4) onto a suitable cribbing in a vertical position. The weight of torque converter assembly (4) is approximately 692 kg (1525 lb).
Show/hide table

Illustration 47 g06286407
Install pilot (3) and bolts (2). Tighten bolts (2) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
Show/hide table

Illustration 48 g06286392
Install two plugs (1).