325, 325B and 325L Excavators Caterpillar

Assembly Procedure For The Final Drive On CIPI Undercarriage Arrangements Which Are Based On 325 Track Type Excavators

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-2420	Transmission Stand Group	1
B	138-7573	Link Bracket	2
C	1P-1860	Retaining Ring Pliers	1
D	1U-5933	Duo-Cone Seal Installer As	1
E	138-7574	Link Bracket	2

Note: Make sure that all of the parts of the final drive are thoroughly clean and free of dirt and debris prior to assembly.

1. Check the condition of all the O-ring seals that are used in the final drive. If any of the O-ring seals are damaged, use new parts for replacement.

Note: If the final drive sprocket was removed from the main housing, refer to Disassembly and Assembly, "Final Drive Sprocket - Remove and Install" in this manual. Follow the installation procedure in order to install the final drive sprocket on the main housing.

2. Assemble the final drive on Tool (A) .

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Illustration 1	g00511934

3. Apply a thin coat of 5P-3931 Anti-Seize Compound to the surfaces inside the main housing that contact bearings (38) and (39). Install bearings (38) and (39) in the bearing's original locations in the main housing with a press. Install the bearings until the bearings contact the counterbore in the main housing.

Note: The rubber seals and all surfaces that contact the seals must be clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals. For more information concerning the assembly and installation of Conventional Duo-Cone Seals, refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.

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Illustration 2	g00513401

4. Install Duo-Cone seal (37) in the main housing with Tool (D) .

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Illustration 3	g00511882

5. Temporarily install main housing (31) with the sprocket on the motor housing. Fasten Tooling (E) and a hoist to main housing (31). Place the main housing and the final drive sprocket in position on the motor housing.

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Illustration 4	g00513390

6. Use a depth micrometer and measure the distance between the hub face and the gear face of gear (34). Take measurements at several locations around the gear. Compute the average of the measured dimensions and record the number. Call this dimension (X) .

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Illustration 5	g00513387

7. Use a depth micrometer and measure the distance between the top face of the motor housing and the bearing inner race. Take measurements at several locations around the motor housing. Compute the average of the measured dimensions and record the number. Call this dimension (Y) .

8. Determine the correct thickness of the shim pack which is made up of shims (35). The shim pack is used between the motor housing and gear (34). Use the following equation to determine the shim pack thickness.

   Shim pack thickness ... (X) - (Y) + 0 to 0.05 mm (0 to 0.002 inch)

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Illustration 6	g00511857

9. Temporarily install the shim pack, which was determined in Step 8, and gear (34) on the motor housing. Only use eight socket head bolts (33) to hold the gear in place. Space the eight bolts equally and tighten the eight socket head bolts evenly.

10. Turn the housing by hand. The housing must turn smoothly. If the housing does not turn smoothly, install a shim which is 0.05 mm (0.002 inch) thinner. Make sure that the shim pack is positioned correctly under gear (34) .

11. Remove gear (34), the shim pack (shims (35) ) and the motor housing from the main housing.

    Note: The rubber seals and all surfaces that contact the seals must be clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals. For more information concerning the assembly and installation of Conventional Duo-Cone Seals, refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.

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Illustration 7	g00513424

12. Install Duo-Cone seal (36) in the motor casing with Tool (D) .

Note: Make sure that the Duo-Cone seals are not scratched or damaged during the assembly of the main housing or during the assembly of the motor housing. After installation of the main housing on the motor housing, there will be a small gap between the components. The gap is caused by the Duo-Cone seals. The gap will be eliminated during installation of gear (34).

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Illustration 8	g00511882

13. Fasten Tooling (E) and a hoist to main housing (31). Place the main housing and the final drive sprocket in position on the motor housing. Make sure that the Duo-Cone seals are not scratched or damaged during installation.

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Illustration 9	g00511872

14. Place shim pack (35), which was determined in Step 8, and gear (34) in the correct position on the motor housing. If two shims were required, put the thinner shim in contact with gear (34). Make sure that all of the holes in the components are in alignment with each other.

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Illustration 10	g00511857

15. Apply a thin coat of 9S-3263 Thread Lock Compound on the threads of 16 socket head bolts (33). Install the socket head bolts that hold gear (34) in place. Tighten the bolts evenly and tighten the bolts in diagonally opposite pairs. tighten the bolts to a torque of 570 ± 79 N·m (420 ± 60 lb ft).

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Illustration 11	g00922246

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Illustration 12	g00572382

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Illustration 13	g00904074

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Illustration 14	g00513451

16. Use the following procedure to assemble carrier assembly (24) .

    1. Apply clean SAE 30 oil on bearings (29). Install two bearings (29) in planetary gear (28) .

    2. Install a thrust washer (27) on each side of planetary gear (28) .

    3. Install planetary gear (28) and thrust washers (27) in carrier (24) .

    Note: If planetary gear (28) has oil grooves "N", make sure that the planetary gear's oil grooves are facing in the correct direction, which was noted during the disassembly of carrier assembly (24) .

    4. Install planetary shaft (26) in carrier (24) and through planetary gear (28). Make sure that the spring pin hole in the planetary shaft is in alignment with the spring pin hole in the carrier.

    5. Install spring pin (25) in carrier (24) and into planetary shaft (26). Install the spring pin until the spring pin is 2.0 mm (0.08 inch) to 3.0 mm (0.12 inch) below the outside surface of the carrier. Orient the split in the spring pin horizontally to the carrier. Align the split in the spring pin so that the split faces either side of the carrier, as shown. Refer to Illustration 14.

    6. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (0.06 inch) from the outside diameter of the spring pin hole.

17. Repeat Steps 16.a through 16.f in order to install the other two planetary gears in carrier (24) .

18. Use two persons to install carrier assembly (24) in the main housing. The weight of the carrier assembly is approximately 36 kg (79 lb).

19. Install O-ring seal (32) in main housing (31) .

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Illustration 15	g00511809

20. Thoroughly clean the mating surface of main housing (31) that contacts ring gear (30). Apply a bead of 1U-8846 Sealant on the mating surface of ring gear (30). Fasten lifting slings and a hoist to ring gear (30). Place the ring gear in position on the main housing. Make sure that the alignment mark on the main housing and the alignment mark on the ring gear line up with each other. It may be necessary to use a soft faced hammer to seat the ring gear on the main housing.

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Illustration 16	g00511788

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Illustration 17	g00572352

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Illustration 18	g00511735

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Illustration 19	g00513451

21. Use the following procedure to assemble carrier assembly (15) .

    1. Install sun gear (23) in carrier (15) .

    2. Use a screwdriver in order to install retaining ring (22) which secures sun gear (23) in the carrier.

    3. Apply clean SAE 30 oil on bearing (21). Install bearing (21) in planetary gear (20) .

    4. Install a thrust washer (19) on each side of planetary gear (20) .

    5. Install planetary gear (20) and thrust washers (19) in carrier (15) .

    Note: If planetary gear (20) has oil grooves "M", make sure that the planetary gear's oil grooves are facing in the correct direction, which was noted during the disassembly of carrier assembly (15) .

    6. Install planetary shaft (18) in carrier (15) and through planetary gear (20). Make sure that the spring pin hole in the carrier is in alignment with the spring pin hole in the planetary shaft.

    7. Install spring pin (17) until the spring pin is 2.0 mm (0.08 inch) to 3.0 mm (0.12 inch) below the outside surface of the carrier. Orient the split in the spring pin horizontally to the carrier. Align the split in the spring pin so that the split faces either side of the carrier, as shown. Refer to Illustration 19.

    8. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (.06 inch) from the outside diameter of the spring pin hole.

22. Repeat Steps 21.a through 21.h in order to install the other two planetary gears in carrier (15) .

23. Place spacer (16) in position on carrier assembly (24). Install carrier assembly (15) in carrier assembly (24). Move the carrier back and forth during the installation in order to ensure that all gears engage properly. Make sure that the carrier assembly is seated properly.

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Illustration 20	g00511653

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Illustration 21	g00572334

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Illustration 22	g00513639

Note: Make sure that retaining ring (9) is installed with the cross section of the ring in the position that is shown. Refer to Illustration 22.

24. Use the following procedure to assemble carrier assembly (7) .

    1. Install sun gear (14) in carrier (7), as shown. Refer to Illustration 20.

    2. Use a screwdriver in order to install retaining ring (13) which secures sun gear (14) in the carrier.

    3. Apply clean SAE 30 oil on bearing (12). Install bearing (12) in planetary gear (11) .

    4. Install a thrust washer (10) on each side of planetary gear (11) .

    5. Install planetary gear (11) and thrust washers (10) on the shaft of carrier (7) .

    Note: If planetary gear (11) has oil grooves "L", make sure that the planetary gear's oil grooves are facing in the same direction, which was noted during the disassembly of carrier assembly (7) .

    6. Use Tool (C) in order to install retaining ring (9) that secures the planetary gear in position. Make sure that retaining ring (9) is installed correctly. Refer to Illustration 22.

25. Repeat Step 24.a through 24.f in order to install the other two planetary gears on carrier assembly (7) .

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Illustration 23	g00511640

26. Install a spacer (8) on each side of sun gear (14) in carrier assembly (7). Install the spacers (8) and carrier assembly (7) in carrier assembly (15). Install sun gear (6) in carrier assembly (7) .

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Illustration 24	g00513653

27. Use a 25.4 mm (1.00 inch) thick straight edge and a depth micrometer in order to measure dimension (P). Dimension (P) is between the upper surface of sun gear (6) and the machined surface of ring gear (30). Record dimension (P) .

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Illustration 25	g00513657

28. Use a 25.4 mm (1.00 inch) thick straight edge and a depth micrometer in order to measure dimension (Q). Dimension (Q) is from the machined surface of cover (2) to the bottom of the insertion hole of thrust plate (5). Record dimension (Q) .

Note: Thrust plate (5) is available in several thicknesses.

29. Determine the correct thickness of thrust plate (5). Use the following equation to determine the thrust plate thickness.

    Thrust plate thickness ... (Q) - (P) - 1.0 mm (0.04 inch) to 2.0 mm (0.08 inch)

30. Use a plastic hammer in order to install the correct thickness of thrust plate (5) in cover (2) .

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Illustration 26	g00511631

31. Put ring gear (4) in position in cover (2). Make sure that all of the mounting bolt holes in both components are in alignment with each other. Apply 9S-3263 Thread Lock Compound on the threads of 12 socket head bolts (3) that hold ring (4) in place. Install the socket head bolts. Tighten the socket head bolts evenly.

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Illustration 27	g00511600

32. Make sure that the machined surface of ring gear (30) is thoroughly clean and dry and that the machined surface is free of dirt and debris. Apply a bead of 1U-8846 Sealant around the machined surface of the ring gear. Fasten Tooling (B) and a hoist to cover (2). Place the cover in the cover's original position on the ring gear. It will be necessary to rotate the cover back and forth in order to engage the planetary gears of carrier assembly (7) with the ring gear in cover (2) .

33. Apply 9S-3263 Thread Lock Compound on the threads of 20 bolts (1) that hold cover (2) in position. Install the washers and bolts. Tighten the bolts evenly to a torque of 570 ± 79 N·m (420 ± 60 lb ft).

End By: Install the final drive. Refer to Disassembly and Assembly, "Final Drive - Install" in this manual.

Assembly Procedure For The Final Drive On CIPI Undercarriage Arrangements Which Are Based On 325B Track Type Excavators

Table 2

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-2420	Transmission Stand Group	1
B	138-7573	Link Bracket	2
C	1P-1860	Retaining Ring Pliers	1
D	1U-5933	Duo-Cone Seal Installer As	1
E	138-7574	Link Bracket	2

Note: Make sure that all of the parts of the final drive are thoroughly clean and free of dirt and debris prior to assembly.

1. Check the condition of all the O-ring seals that are used in the final drive. If any of the O-ring seals are damaged, use new parts for replacement.

Note: If the final drive sprocket was removed from the main housing, refer to Disassembly and Assembly, "Final Drive Sprocket - Remove and Install" in this manual. Follow the installation procedure in order to install the final drive sprocket on the main housing.

2. Assemble the final drive on Tool (A) .

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Illustration 28	g00511934

3. Apply 5P-3931 Anti-Seize Compound to the surfaces inside the main housing that contact bearings (38) and (39). Install bearings (38) and (39) in the bearing's original locations in the main housing with a press. Install the bearings until the bearings contact the counterbore in the main housing.

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Illustration 29	g00511872

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Illustration 30	g00511857

4. Use the following procedure to determine the correct bearing preload and the correct thickness of shims (35) that are used under gear (34) .
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   Illustration 31	g00511882

   1. Fasten Tool (E) and a hoist to main housing (31), as shown. Install the main housing on the motor housing.

   2. Use a suitable press and a spacer to apply a load of 4000 kg (8820 lb) on bearing (38) .

   3. Rotate the main housing in order to seat the bearings.

   4. Reduce the load on bearing (38) to 1000 ± 100 kg (2200 ± 220 lb).
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   Illustration 32	g00513387

   5. Maintain the load on bearing (38). Measure the distance between the top face of the motor housing and the bearing inner race. Use a depth micrometer to take this measurement in several locations around the bearing. Compute the average of the measured dimensions and record the number. Call this dimension (Y) .
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   Illustration 33	g00513390

   6. Use a depth micrometer and measure the distance between the hub face and the gear face of gear (34). Take measurements at several locations around the gear. Compute the average of the measured dimensions and record the number. Call this dimension (X) .

   7. Determine the correct thickness of the shim pack which is made up of shims (35). The shim pack is used between the motor housing and gear (34). Use the following equation to determine the shim pack thickness.

      Shim pack thickness ... (Y) - (X) ± 0.05 mm (.002 inch)

      Note: If two shims are required, install the thinner shim next to gear (34) when the gear is installed.

5. Remove the main housing from the motor housing.

Note: The rubber seals and all surfaces that contact the seals must be clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals. For more information concerning the assembly and installation of Conventional Duo-Cone Seals, refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install" in this manual.

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Illustration 34	g00513401

6. Install Duo-Cone seal (37) in the main housing with Tool (D) .

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Illustration 35	g00513424

7. Install Duo-Cone seal (36) in the motor casing with Tool (D) .

Note: Make sure that the Duo-Cone seals are not scratched or damaged during the assembly of the main housing or during the assembly of the motor housing. After installation of the main housing on the motor housing, there will be a small gap between the components. The gap is caused by the Duo-Cone seals. The gap will be eliminated during installation of gear (34).

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Illustration 36	g00511882

8. Fasten Tooling (E) and a hoist to main housing (31). Place the main housing and the final drive sprocket in position on the motor housing. Make sure that the Duo-Cone seals are not scratched or damaged during installation.

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Illustration 37	g00511872

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Illustration 38	g00511857

9. Apply 5P-3931 Anti-Seize Compound on the four pins in gear (34) .

10. Place shim pack (35), which was determined in Step 4.a through 4.g, and gear (34) in the correct position on the motor housing. If two shims were required, put the thinner shim in contact with gear (34). Make sure that all of the holes in the components are in alignment with each other.

11. Apply 9S-3263 Thread Lock Compound on the threads of 16 socket head bolts (33). Install the socket head bolts in order to hold gear (34) in place. Tighten the bolts evenly and tighten the bolts in diagonally opposite pairs.

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Illustration 39	g00511825

12. Install O-ring seal (32) in main housing (31) .

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Illustration 40	g00511809

13. Thoroughly clean the mating surface of main housing (31) that contacts ring gear (30). Apply a bead of 1U-8846 Sealant on the mating surface of ring gear (30). Fasten lifting slings and a hoist to ring gear (30). Place the ring gear in position on the main housing. Make sure that the alignment mark on the main housing and the alignment mark on the ring gear line up with each other. It may be necessary to use a soft faced hammer to seat the ring gear on the main housing.

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Illustration 41	g00922246

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Illustration 42	g00572382

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Illustration 43	g00511799

14. Use the following procedure to assemble carrier assembly (24) .

    1. Apply clean SAE 30 oil on bearings (29). Install two bearings (29) in planetary gear (28) .

    2. Install thrust washer (27) on each side of planetary gear (28) .

    3. Install planetary gear (28) and thrust washers (27) in carrier (24) .

    Note: If planetary gear (28) has oil grooves "N", make sure that the planetary gear's oil grooves are facing in the correct direction, which was noted during the disassembly of carrier assembly (24) .

    4. Install planetary shaft (26) in carrier (24) and through planetary gear (28). Make sure that the spring pin hole in the planetary shaft is in alignment with the spring pin hole in the carrier.

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Illustration 44	g00513451

15. Install spring pin (25) in the carrier and into the planetary shaft. Install the spring pin until the spring pin is even with the outside surface of the carrier. Orient the split in the spring pin horizontally to the carrier. Align the split in the spring pin so that the split faces either side of the carrier, as shown.

16. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (.06 inch) from the outside diameter of the spring pin hole.

17. Repeat Steps 16 through 16 in order to install the other two planetary gears in carrier (24) .

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Illustration 45	g00511795

18. Install carrier assembly (24) in ring gear (30). Slide a piece of steel bar stock between the planetary gears in carrier assembly (24), as shown. Make sure that the bar stock is centered in the carrier assembly. Fasten a lifting sling and a hoist to the steel bar stock, as shown. Lower the carrier assembly into position in the ring gear. It may be necessary to move the carrier assembly back and forth during installation in order to ensure that all gears align and all gears mesh properly. Make sure that the carrier assembly is seated properly.

19. Install spacer (16) in carrier assembly (24), as shown.

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Illustration 46	g00511788

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Illustration 47	g00572352

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Illustration 48	g00511735

20. Use the following procedure to assemble carrier assembly (15) .

    1. Install sun gear (23) in carrier (15) .

    2. Use a screwdriver in order to install retaining ring (22) which secures sun gear (23) in the carrier.

    3. Apply clean SAE 30 oil on bearing (21). Install bearing (21) in planetary gear (20) .

    4. Install thrust washer (19) on each side of planetary gear (20) .

    5. Install planetary gear (20) and thrust washers (19) in carrier (15) .

    Note: If planetary gear (20) has oil grooves "M", make sure that the planetary gear's oil grooves are facing in the correct direction, which was noted during the disassembly of carrier assembly (15) .

    6. Install planetary shaft (18) in carrier (15) and through planetary gear (20). Make sure that the spring pin hole in the carrier is in alignment with the spring pin hole in the planetary shaft.

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Illustration 49	g00513451

21. Install spring pin (17) in the carrier and into the planetary shaft. Install the spring pin until the spring pin is even with the outside surface of the carrier. Orient the split in the spring pin horizontally to the carrier. Align the split in the spring pin so that the split faces either side of the carrier, as shown.

22. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (.06 inch) from the outside diameter of the spring pin hole.

23. Repeat Steps 21 through 22 in order to install the other two planetary gears in carrier (15) .

24. Install carrier assembly (15) in carrier assembly (24). Move the carrier back and forth during the installation in order to ensure that all gears engage properly. Make sure that the carrier assembly is seated properly.

25. Install spacer (8) in the top side of carrier assembly (15) .

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Illustration 50	g00511653

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Illustration 51	g00572334

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Illustration 52	g00513639

Note: Make sure that retaining ring (9) is installed with the cross section of the ring in the position that is shown. Refer to Illustration 22.

26. Use the following procedure to assemble carrier assembly (7) .

    1. Install sun gear (14) in carrier (7), as shown. Refer to Illustration 20.

    2. Use a screwdriver in order to install retaining ring (13) which secures sun gear (14) in the carrier.

    3. Apply clean SAE 30 oil on bearing (12). Install bearing (12) in planetary gear (11) .

    4. Install thrust washer (10) on each side of planetary gear (11) .

    5. Install planetary gear (11) and thrust washers (10) on the shaft of carrier (7) .

    Note: If planetary gear (11) has oil grooves "L", make sure that the planetary gear's oil grooves are facing in the same direction, which was noted during the disassembly of carrier assembly (7) .

    6. Use Tool (C) in order to install retaining ring (9) that secures the planetary gear in position. Make sure that retaining ring (9) is installed correctly. Refer to Illustration 22.

27. Repeat Step 24 in order to install the other two planetary gears on carrier assembly (7) .

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Illustration 53	g00511640

28. Install spacer (8) in carrier assembly (7) .

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Illustration 54	g00511636

29. Install carrier assembly (7) in carrier assembly (15). Make sure that the carrier assembly is seated properly. Install sun gear (6) in carrier assembly (7) .

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Illustration 55	g00513653

30. Use a 25.4 mm (1.00 inch) thick straight edge and a depth micrometer in order to measure dimension (P). Dimension (P) is between the upper surface of sun gear (6) and the machined surface of ring gear (30). Record dimension (P) .

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Illustration 56	g00513657

31. Use a 25.4 mm (1.00 inch) thick straight edge and a depth micrometer in order to measure dimension (Q). Dimension (Q) is from the machined surface of cover (2) to the bottom of the insertion hole of thrust plate (5). Record dimension (Q) .

Note: Thrust plate (5) is available in several thicknesses.

32. Determine the correct thickness of thrust plate (5). Use the following equation to determine the thrust plate thickness.

    Thrust plate thickness ... (Q) - (P) - 1.0 mm (0.04 inch) to 2.0 mm (0.08 inch)

33. Use a plastic hammer in order to install the correct thickness of thrust plate (5) in cover (2) .

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Illustration 57	g00511631

34. Put ring gear (4) in position in cover (2). Make sure that all of the mounting bolt holes in both components are in alignment with each other. Apply 9S-3263 Thread Lock Compound on the threads of 12 socket head bolts (3) that hold ring (4) in place. Install the socket head bolts. Tighten the socket head bolts evenly.

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Illustration 58	g00511600

35. Make sure that the machined surface of ring gear (30) is thoroughly clean and dry and that the machined surface is free of dirt and debris. Apply a bead of 1U-8846 Sealant around the machined surface of the ring gear. Fasten Tooling (B) and a hoist to cover (2). Place the cover in the cover's original position on the ring gear. It will be necessary to rotate the cover back and forth in order to engage the planetary gears of carrier assembly (7) with the ring gear in cover (2) .

36. Apply 9S-3263 Thread Lock Compound on the threads of 20 bolts (1) that hold cover (2) in position. Install the washers and bolts. Tighten the bolts evenly to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

End By: Install the final drive. Refer to Disassembly and Assembly, "Final Drive - Install" in this manual.

Assembly Procedure For The Final Drive On CIPI Undercarriage Arrangements Which Are Based On 325C Track Type Excavators

Table 3

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-2420	Transmission Repair Stands	1
B	138-7573	Link Brackets	2
C	126-3994	Duo-Cone Seal Installer	1
D	1P-1863	Retaining Ring Pliers	1
E	138-7574	Link Bracket	2
F	194-3878	Spanner Socket	1
G	194-3884	Spacer	1
H	6V-7030	Micrometer Depth Gauge	1
J	FT-2770	Leak Test	1

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.

Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.

Note: Apply a light film of hydraulic oil to all components before assembly.

1. Install the final drive sprocket if the sprocket was removed from the sprocket housing.

   Reference: Refer to Disassembly and Assembly, "Final Drive Sprocket - Remove and Install" in this manual for the installation of the final drive sprocket.

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Illustration 59	g00782138

2. Apply 5P-3931 Anti-Seize Compound to the outer diameter of the bearings.

3. Install bearings (41) and (40) in the original locations in sprocket housing (37) with a press.

4. Make sure that bearing (41) and bearing (40) contact the counterbore in the main housing.

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Illustration 60	g00782249

5. Install two Duo-Cone seal kit (39) with Tooling (C) .

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Illustration 61	g00782377

6. Install Duo-Cone seal kit (39) with Tooling (C) onto housing (38) .

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Illustration 62	g00879371

7. Install Tooling (E) to housing (36). Install housing (36) onto sprocket housing (37). Install sprocket housing (37) and housing (36) onto housing (38). The weight of housing (36) and (37) is approximately 118 kg (260 lb).

8. Remove Tooling (E) from housing (36) .

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Illustration 63	g00782386

9. Install stopper plate assembly (35). Do not tighten stopper plate assembly (35 ) at this time.

   Note: Stopper plate assembly (35) will secure sprocket housing (36) to motor housing (38) .

10. Install housing (36) and sprocket housing (37) in a press.

11. Secure motor housing (38) and sprocket housing (37) in the press. Remove stopper plate assembly (35) .

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Illustration 64	g00782460

12. Secure Tooling (G) to Tooling (F). Tooling (G) will replace stopper plate assembly (35) in order to obtain a measurement.

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Illustration 65	g00782390

13. Install Tooling (F) and Tooling (G) .

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Illustration 66	g00782399

14. Apply a force of 4000 kg (8818 lb) to the top of Tooling (F). Rotate sprocket housing (37) in order to seat the bearings.

15. Reduce the force on the top of Tooling (F) to 1000 kg (2205 lb).

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Illustration 67	g00782424

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Illustration 68	g00782421
This is a view of position (W) .

16. Install Tooling (H). Measure Dimension (W). Dimension (W) is the distance from the top of Tooling (F) to the top of motor housing (38). Record Dimension (W) .

17. Repeat Step 16 in the other two holes in the top of Tooling (F). Record Dimension (W) .

18. Calculate the average of Dimension (W). Retain this average dimension.

19. Remove Tooling (F) and Tooling (G) from the press and the housing.

20. Separate Tooling (F) from Tooling (G) .

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Illustration 69	g00782545

21. Use a micrometer in order to measure the thickness of Tooling (G). This will be Dimension (X). Record Dimension (X) .

22. Repeat Step 21 at two other positions on Tooling (G). Record Dimension (X) .

23. Calculate the average of Dimension (X). Retain this average Dimension.

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Illustration 70	g00782568

Note: A new stopper plate assembly should be used.

24. Use a micrometer in order to measure the thickness of stopper plate assembly (35). Record this dimension as Dimension (Y) .

25. Repeat Step 24 at two other positions on stopper plate assembly (35). Record Dimension (Y) .

26. Calculate the average of Dimension (Y). Retain this average dimension.

27. Subtract the average Dimension (Y) from the average Dimension (X). Retain this dimension. This dimension will be Dimension (Z) .

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Illustration 71	g00782606

28. Install stopper plate assembly (35) onto housing (38). Begin by installing the plate by hand in order to prevent damage to the threads.

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Illustration 72	g00782390

29. Install Tooling (F). Engage Tooling (F) into stopper plate assembly (35) .

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Illustration 73	g00782608

30. Install Tooling (H) into Tooling (F). Install a large ratchet into Tooling (F).

    Note: Motor housing (38) must be secured to the press.

31. Use the following procedure to achieve the proper setting bearing preload. The preload is determined by a measurement.

    1. Determine the average Dimension (W) .

    2. Determine the Dimension (Z) .

    3. If Dimension (Z) is positive, subtract Dimension (Z) from the average Dimension (W) in order to calculate Dimension (V) .

    4. If Dimension (Z) is negative add Dimension (Z) from the average Dimension (W) in order to calculate Dimension (V) .

    5. Tighten plate assembly (35) with Tooling (F) until the average of the measurements with Tooling (H) is equal to Dimension (V). A tolerance of 0.05 mm (0.0020 inch) is permitted.

32. Remove Tooling (F) and Tooling (H) from the housing.

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Illustration 74	g00782667

33. Perform a peening operation on stopper plate assembly (35) at the point of the arrow with a round nose punch.

    Note: The peening operation will prevent any movement of stopper plate assembly (35) .

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Illustration 75	g00782731

34. Install Tooling (D) on housing (36). Lift sprocket housing (37) from the press. Install the housing on Tooling (A). Secure sprocket housing (37) to Tooling (A) .

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Illustration 76	g00781807

35. Install O-ring seal (34) in housing (36) .

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Illustration 77	g00781730

36. Install gear (33) on housing (36).

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Illustration 78	g00781719

37. Assemble carrier assembly (27), as follows.
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    Illustration 79	g00781607

    1. Use a deburring tool in order to remove the metal burr from the openings in the carrier.

    2. Install two bearings (31) in planetary gear (32) .

    3. Install two thrust washers (30) and planetary gear (32) in the carrier assembly.

    4. Install planetary shaft (28) in the carrier assembly.

    5. Drive spring pin (29) into planetary shaft (28) with a hammer and a punch.
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    Illustration 80	g00903073

    6. Align the split in spring pin (29) to the top or to the bottom. Make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (0.059 inch) from the outside diameter of the spring pin hole.

38. Repeat steps 37.a through 37.f in order to install the other two planetary gears in the carrier.

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Illustration 81	g00781559

39. Install carrier assembly (27) in gear (33). The weight of the carrier is approximately 38 kg (85 lb).

    Note: It will be necessary to use an appropriate lifting device or two people to install carrier assembly (27) .

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Illustration 82	g00781529

40. Install spacer (26). Install gear (25) .

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Illustration 83	g00781466

41. Assemble carrier assembly (19), as follows.
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    Illustration 84	g00781516

    1. Use a deburring tool in order to remove the metal burr from the openings in the carrier.

    2. Install bearing (23) in planetary gear (24) .

    3. Install two thrust washers (22) and planetary gear (24) in the carrier assembly.

    4. Install planetary shaft (21) in the carrier assembly.
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    Illustration 85	g00879368

    5. Drive spring pin (20) into planetary shaft (21) with a hammer and a punch.
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    Illustration 86	g00903073

    6. Align the split in the spring pin to the top or to the bottom. Make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately 1.5 mm (0.059 inch) from the outside diameter of the spring pin hole.

    7. Repeat steps 41.a through 41.f in order to install the other two planetary gears in the carrier.

42. Install carrier assembly (19) into gear. The weight of carrier assembly (19) is approximately 14 kg (30 lb).

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Illustration 87	g00781466

43. Install retaining ring (18). Retaining ring (18) will secure carrier assembly (19) in position.

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Illustration 88	g00781412

44. Install spacer (17). Install gear (16) .

45. Assemble carrier assembly (15), as follows.
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    Illustration 89	g00781407

    1. Install carrier assembly in position on gear (16) .
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    Illustration 90	g00781401

    2. Install retaining ring (14) onto gear (16) .
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    Illustration 91	g00780432

    3. Install washer (11). Install bearing assembly (13). Install gear (12). Install washer (11). Install retaining ring (10) with Tooling (D) .

    4. Repeat Steps 45.a through 45.c for the other two planetary gears.

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Illustration 92	g00780428

46. Install spacer (9). Install gear (8) .

47. Apply 1U-8846 Gasket Sealant to the mating surfaces of cover (2) and housing (36) .

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Illustration 93	g00879365

48. Install O-ring seal (7) on plug (4) .

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Illustration 94	g00879362

49. Install plug (4) in cover (2). Replace plate (6) if wear is shown. Position gear (5). Install bolts (3) .

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Illustration 95	g00708090

50. Install cover (2) with Tooling (B). The weight of the cover is approximately 32 kg (70 lb).

51. Remove cover (2) .

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Illustration 96	g00783116

52. Adjust clearance between plate (5) and gear (8) between 1.000 + 1.000 mm (0.0394 + 0.0394 inch).

53. Attach Tooling (B) to cover (2). Install cover (2), as shown. The weight of cover (2) is approximately 32 kg (70 lb).

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Illustration 97	g00708089

54. Install bolts (1) and the washers. Tighten bolts (1) in a crisscross pattern to a torque of 420 ± 60 N·m (310 ± 44 lb ft). Tighten new bolts (1) and additional 60 degrees.

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Illustration 98	g00783362

55. Remove plug (6). Attach Tooling (J) to cover (2). Reduce the air pressure at the source to 103 kPa (15 psi). Apply air pressure to Tooling (J). This air will test the Duo-Cone seal kits.

56. Use the ball valve on Tooling (J) to eliminate the air pressure to the final drive. A pressure of 98 kPa (14.2 psi) must be maintained for 30 seconds.

57. Remove Tooling (J). Install plug (6). Torque plug (6) to 80 ± 10 N·m (59 ± 7 lb ft).

58. Remove the final drive from Tooling (A). The combined weight of the final drive and final drive sprocket is approximately 310 kg (683 lb).

End By: Install the final drive. Refer to Disassembly and Assembly, "Final Drive - Install".