797 Off-Highway Truck Power Train Caterpillar

Illustration 1	g01014493

Illustration 2	g02038054
View A-A

Illustration 3	g02038067
View B-B

Illustration 4	g02038075
View C-C

Apply Loctite 263 or Loctite 270 (Europe only) to the following bolts during assembly.

(1) Quantity ... 6

(2) Quantity ... 9

(3) Quantity ... 3

(4) Quantity ... 4

(5) Quantity ... 3

(7) Quantity ... 17

(9) Quantity ... 3

(6) Apply Loctite 536 to elbows during assembly.

(8) Apply Loctite 536 to elbows during assembly.

Illustration 5	g02038133
View D-D

(10) Torque for five bolts ... 50 ± 10 N·m (37 ± 7 lb ft)

Note: Apply Loctite 263 or Loctite 270 (Europe only) to bolts (10) during assembly.

(11) Torque for ten bolts ... 50 ± 10 N·m (37 ± 7 lb ft)

Note: Apply Loctite 263 or Loctite 270 (Europe only) to bolts (11) during assembly.

(12) Apply Loctite 263 or Loctite 270 (Europe only) to the two bolts during assembly.

(13) 7G-6887 Spring

Length under test force ... 60 mm (2.4 inch)

Test force ... 2660 ± 213 N (60 ± 48 lb)

Free length after test ... 95.9 mm (3.78 inch)

Outside diameter ... 76.33 mm (3.01 inch)

Note: Install spring assembly (13) after the differential and bevel gear is mounted in the rear axle housing.

(14) Torque for bolt ... 50 ± 10 N·m (37 ± 7 lb ft)

Note: Apply Loctite 263 or Loctite 270 (Europe only) to bolts (14) during assembly.

Illustration 6	g06199022
Section E-E

(15) 156-2900 Shim Pack

Total thickness ... 4.84 mm (0.191 inch)

Note: See the Adjustment Procedure for the Bevel Gear Backlash in the Power Train Disassembly and Assembly, "Differential and Bevel Gear Assemble" in order to determine the number of shims to use.

(17) 156-2899 Shim Pack

Total thickness ... 4.84 mm (0.191 inch)

Note: See the Adjustment Procedure for the Bevel Gear Backlash in the Power Train Disassembly and Assembly, "Differential and Bevel Gear Assemble" in order to determine the number of shims to use.

(18) 156-2898 Shim Pack

Total thickness ... 4.84 mm (0.191 inch)

Note: See the Adjustment Procedure for the Bevel Pinion Bearings in the Power Train Disassembly and Assembly, "Differential and Bevel Gear Assemble" in order to determine the number of shims to use.

Illustration 7	g06199053
Section F-F

(19) Relief valve for differential lube oil flow

Maximum pressure setting ... 689 ± 25 kPa (100 ± 4 psi)

Final installation torque ... 48 ± 7 N·m (35 ± 5 lb ft)

Illustration 8	g06199054
Detail G

(20) Seal

(21) Screen assembly

(22) Mating surfaces

Note: Install screen assembly (21) after gear group is mounted in axle housing.

Illustration 9	g06199055
Section H-H

(23) Bushing

(24) Spacer

Note: Apply graphite and petrolatum mixture of NLGI No. 2 consistency to outside diameter of spacer (24) prior to installation of bushing (23).

(25) Apply Loctite 263 or Loctite 270 (Europe only) to threads of bolt during assembly.

(26) Apply Loctite 263 or Loctite 270 (Europe only) to threads of bolt during assembly.

Illustration 10	g06390064
Detail J

(27) Prior to assembly, lubricate the seal lightly with the lubricant that is being sealed.

(28) Prior to assembly, apply Loctite 620 to inside diameter of wear sleeve. Drive the wear sleeve onto the shaft until the wear sleeve is flush with the end of the pinion housing.

Illustration 11	g06199059
Detail K

(29) 156-6455 Shim ... 5.096 ± 0.013 mm (0.2006 ± 0.0005 inch)

(30) Shim thicknesses

156-6452 Shim ... 3.000 ± 0.013 mm (0.1181 ± 0.0005 inch)

156-6453 Shim ... 3.050 ± 0.013 mm (0.1201 ± 0.0005 inch)

156-6454 Shim ... 3.100 ± 0.013 mm (0.1220 ± 0.0005 inch)

165-2319 Shim ... 3.200 ± 0.013 mm (0.1260 ± 0.0005 inch)

204-1557 Shim ... 3.300 ± 0.013 mm (0.1299 ± 0.0005 inch)

Note: See the Adjustment Procedure for Bevel Pinion Bearings in the Power Train Disassembly and Assembly, "Differential and Bevel Gear Assemble" in order to determine the number of shims to use.