Usage:
Introduction
This instruction gives the procedure for repairing/improving the retarder and transfer gear group.
Reference: See Parts Book, Service Manual.
Use the 657E Scraper Power Train Disassembly and Assembly (D & A) Service Manual module, form SENR2691. Applicable sections will be called out at the beginning of each procedure.
A 5P9736 Link Bracket is needed to remove the retarder and transfer gears from the power pack.
Removal of Retarder and Transfer Gears
1. Use the procedure in the Retarder Control Valve section of the D & A module to remove the retarder control valve from the retarder and transfer gear group.
2. Use 5P9736 Link Bracket and the procedure in the Engine Transfer Gears section of the D & A module to remove the retarder and transfer gear group.
Disassembly of Retarder and Transfer Gears
1. See the Engine Transfer Gears section of the D & A module for a list of tools needed to remove bearing cups and cones.
2. Follow the procedure in the Engine Transfer Gears section of the D & A module to remove parts from the housing.
3. If debris and/or damage are seen inside the gear group, check the transmission screens and filters to see if the transmission is contaminated.
Modification of Retarder and Transfer Gear Housing
There are six areas where the housing requires modification:
- * Upper idler bore (1) to accommodate a new gear, shaft, bearing and nut assembly.
- * Drilled hole (2) for the pin on the nut assembly.
- * Bore (3) enlarged for screen assembly and seal area changed.
- * Bore (4) enlarged for other screen assembly and seal area changed.
- * Check drill size in housing passage (5).
- * Part number (6) on housing changed.
- * Drilled hole (2) for the pin on the nut assembly.
1. Two different housings (6G2556 and 5T8384) are used in the affected product. The housing part number is put on the housing in raised markings. See the above illustration for location. The earlier housing (6G2556) requires additional machining in the upper idler bore.
Use step 3 for 6G2556 Housing only.
2. Fasten face (A) of the housing to a bedplate and machine the upper idler bore perpendicular to face (A). Locate the position of the bore off bore (B) (6G2556 Housing) or bore (C) (5T8384 Housing).
3. Machine the upper idler bore of the 6G2556 Housing to the dimension given in the illustration above.
4. Machine the upper idler bore of the housing to the dimension given in the illustration above. Machine off any thin slivers of metal left at area (E).
NOTE: On 5T8384 Housings, there will be a small area at location (D) that will not machine (clean up). The original diameter was 99.0 mm (3.90") while the new diameter for the start of the angle is 95.0 mm (3.74").
5. Use an appropriate drill for bore (G) so the hole can be reamed out to the dimensions shown. The center of bore (G) is on the center line of bores (F) and (H).
6. Locate the center of bore (K) from existing bore and machine to the dimension shown. Also change seal area per Section S-S.
7. Remove housing from bedplate. Turn housing over and fasten face (M) to a bedplate.
8. Locate center of bore (N) from existing bore and machine to the dimension shown. Also change seal area per Section T-T.
9. Check the size of drilled passage (5). A 3.4 mm (1/8" or #30) drill bit should fit in the drilled passage. If not, use the bit to drill out the passage.
10. Grind off part number (raised markings) and stamp part number 8W3552 in approximate location of previous part number.
Assembly of Retarder and Transfer Gears and Set End Play on Gear Shaft Bearings
See the Engine Transfer Gears section of the D & A module for a list of tools needed to install bearings and measure bearing end play.
NOTE: Before starting assembly, lower the temperature of the bearing cups to approximately 4°C (40°F).
Follow the procedure below and use Chart A and the parts book or a fiche copy for correct assembly.
1. Install Bearing Assembly (8) in Gear (22) with Ring (14) between the cups.
2. Install Nut Assembly (23) in housing so alignment pin (not shown) fits in drilled hole in housing.
3. Put Gear (22) and Bearing Assembly (8) into housing and put Shaft (9) with Seal (10) into housing so shaft slides through bearing cones and against Nut Assembly (23).
4. Install Bolt (12) with Seal (11) and Washer (13) so bolt goes through Shaft (9) into Nut Assembly (23) to hold parts in alignment. DO NOT tighten bolt at this time.
5. Note D: Tighten six bolts.
6. Tighten Bolt (12) to a torque of 425 ± 40 N·m (320 ± 15 lb ft). Upper idler shaft installation must be complete before assembling other gears.
7. Assemble other gears using the following NOTES as applicable:
NOTE A: Assemble two bolts into cage and tighten to 34 N·m (25 lb ft). Rotate the gear three revolutions. Tighten two additional bolts to 34 N·m (25 ft lb) and rotate the gear three more revolutions. Remove the bolts and the cage. Install 0.51 mm (0.020") shims and tighten the six bolts in the cage to 34 N·m (25 ft lb). Install a dial indicator to check end play. Apply a light load on the end of the gear while rotating the gear. Then apply the load in the opposite direction while rotating the gear. Bearing end play must be 0.08 ± 0.05 mm (0.003 ± 0.002"). Remove shims if necessary and check end play again. Tighten bolts to specification.
NOTE F: Coat splines with 5P0960 Lubricant at assembly.
NOTE G: Lubricate sealing lip lightly with lubricant used for transfer gears.
NOTE E: To obtain bearing end play, assembly cage with two bolts and tighten to 34 N·m (25 lb ft). Rotate gear three revolutions. Tighten two additional bolts to 34 N·m (25 lb ft) and rotate gear three more revolutions. Remove torque from all four bolts and then tighten two bolts, 180 degrees apart, to 1.7 N·m (15 in lb). Rotate gear three revolutions and retighten to 3.4 N·m (30 in lb). Rotate gear three more revolutions and tighten again to 3.4 N·m (30 in lb). Measure end gap between the cage and housing at the two bolts with torque. Average these two measurements and install shims with thickness equal to the average plus 0.18 mm (.007"). The final end play must be 0.08 mm ± 0.05 mm (.003 ± .002"). Tighten bolts to specification.
NOTE B: Apply 9S3263 Thread Sealant.
New screen assemblies are used with the Retarder and Transfer Gear Group. Refer to the illustration and chart above for a list of new parts plus seals to be replaced.
Installation of Retarder and Transfer Gear Group
2. To install Retarder and Transfer Gear Group, use 5P9736 Link Bracket and the procedure in the Engine Transfer Gears section of the D & A module.
3. To install the retarder control valve on the Retarder and Transfer Gear Group, use the procedure in the Retarder Control Valve section of the D & A module.