966G and 972G Wheel Loaders Power Train Caterpillar

Assembly Procedure

Note: The axle housing assemblies that are used in the fixed axle and in the oscillating axle are similar. Therefore, both axle assemblies can be assembled in the same manner.

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Illustration 1	g00450765

1. Fasten the axle shaft in Tooling (B) .

2. Heat bearing cone (18) to a maximum temperature of 135°C (275°F).

3. Install bearing cone (18) on the axle shaft, as shown. The bearing cone must be seated against the shoulder on the axle shaft.

Note: Allow the bearing cone and the axle to reach a uniform temperature.

4. Use a suitable driver or a press in order to reset the bearing cone. This will ensure that the bearing cone is seated properly.

5. Apply clean SAE 30 oil on bearing cone (18) in order to prevent rust.

Note: Make sure that the rubber seals and all surfaces that contact the seals are clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals.

6. Use Tooling (F) in order to install the Duo-Cone seal (19) on the axle assembly. Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".

Note: The following steps are for the installation of the ring gear.

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Illustration 2	g00451054

Note: Dowels (15) are used to locate ring gear (14) in position.

7. Locate the position of ring gear (14) in relation to the axle housing. Align the holes in order to install dowels (15) . Place alignment marks on ring gear (14) and the axle housing in order to ensure correct installation.

8. Lower the temperature of ring gear (14) . The correct temperature is -70°C (-94°F). Install ring gear (14) in the axle housing.

9. Install dowels (15) . Stake the axle housing in order to retain the dowels.

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Illustration 3	g00450763

10. Lower the temperature of bearing cup (16) . Install bearing cup (16) in the end of the axle housing. The bearing cup must be seated against the shoulder of the mating surface.

Note: Allow the bearing cone and the axle to reach a uniform temperature.

11. Use a suitable driver or press in order to reset bearing cup (16) . This will ensure that bearing cup (16) is seated properly.

Note: Make sure that the rubber seals and all surfaces that contact the seals are clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals.

12. Use Tooling (F) in order to install Duo-Cone seal (17) in the end of the axle housing. Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".

13. Lower the temperature of bearing cup (13) . Install bearing cup (13) in the opposite end of the axle housing. The bearing cup must be seated against the shoulder of the mating surface.

    Note: Allow the bearing cone and the axle to reach a uniform temperature.

14. Use a suitable driver or a press in order to reset bearing cup (13) . This will ensure that bearing cup (13) is seated properly.

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Illustration 4	g00451125

15. Install Tooling (A) and a suitable lifting device (not shown) to the axle housing.

16. Use the hoist in order to install the axle housing on the axle shaft. The weight of the axle housing is approximately 136 kg (300 lb).

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Illustration 5	g00450748

17. Heat bearing cone (12) . The maximum temperature is 135°C (275°F).

18. Install bearing cone (12) on the axle shaft so that there is slight end play. When bearing cone (12) is cool, apply clean SAE 30 oil to the bearing cone.

    Note: The adjusting nut must be installed so that the part number is facing away from bearing cone (12) .

19. Install two bolts of a suitable size in the rim of the axle flange. This will prevent the axle shaft from turning while the bearing nut (11) is tightened.

20. Apply clean SAE 30 oil on bearing nut (11) . Install bearing nut (11) on the axle shaft. Tighten the nut until a small amount of end play remains.

21. The seal drag torque is the torque that is needed to rotate the axle housing. Use one of the following methods to measure the seal drag torque:

    1. To measure seal drag torque, install Tooling (G) on the axle housing. Place a torque wrench on the bolt at the center of the bar. Use the torque wrench in order to rotate the housing. Record the reading of the torque wrench. The reading on the torque wrench is the seal drag torque.

    2. To measure seal drag torque, install a bolt and a nut through an outer mounting hole on the axle housing. Install a torque wrench on the bolt. Make sure that the handle is aligned with the center of the axle shaft. Use the torque wrench in order to rotate the housing. Record the reading on the torque wrench. Use the following formula in order to calculate the actual seal drag torque:
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       Table 2

       	"SDT ="	C × (B + A)
       		B

       "SDT" is the actual seal drag torque in newton meters (N·m).

       "C" is the torque wrench reading in newton meters (N·m).

       "B" is the length of the torque wrench in meters.

       "A" is the bolt circle radius of axle housing (2) in meters. This is equal to 0.229 m (9.016 inch).

22. Tighten nut (11) by using one of the following methods:

    1. Rotate the axle housing. Use Tooling (E) in order to tighten bearing nut (11) . Install Tooling (G) on the axle housing. Place a torque wrench on the bolt at the center of Tooling (G) . The torque wrench reading is equal to the seal drag torque plus the axle bearing preload rolling torque. Use the seal drag torque that was recorded in Step 21.

       Note: The preload rolling torque for new bearings is 7 to 13 N·m (5.2 to 9.6 lb ft). The preload rolling torque for used bearings is 3.5 to 6.5 N·m (2.6 to 4.8 lb ft).

    2. Use the torque wrench in order to rotate the axle housing. Use Tooling (E) in order to tighten nut (11) . The torque wrench reading must equal the axle bearing preload rolling torque plus the actual seal drag torque. Use the seal drag torque that was recorded in Step 21. Use the following formula to calculate the required torque wrench reading. This formula is used to measure torque at the bolt circle.
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       Table 3

       	"C ="	B × (T + SDT)
       		B + A

       "C" is the torque wrench reading in newton meters (N·m).

       "B" is the length of the torque wrench in meters.

       "A" is the bolt circle radius of axle housing (2) in meters. This equals 0.229 m (9.0160 inch).

       "SDT" is the actual seal drag torque in newton meters (N·m).

       "T" is the axle bearing preload rolling torque. The preload rolling torque for new bearings is 9 to 16 N·m (7 to 12 lb ft). The preload rolling torque for used bearings is 4.5 to 8 N·m (3.5 to 6 lb ft).

23. Make sure that axle shaft (4) has zero end play.

24. If the axle bearing preload rolling torque exceeds the specification, back off nut (11) by 1/8 turn and reseat bearing cone (12) against nut (11) . Perform Step 22 again.

25. The following steps are for the assembly of planetary carrier assembly (5) :
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    Illustration 6	g00450743

    1. Install retaining ring (3) in the carrier.
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    Illustration 7	g00450726

    2. Apply a thin coat of clean SAE 30 oil on all parts of planetary carrier assembly (5) .

    3. Install bearing (10) in planetary gear (9) .

    4. Install thrust washers (8) , planetary gear (9) , and shaft (7) in planetary carrier assembly (5) .
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    Illustration 8	g00450669

    5. Install shaft (7) in the carrier. Make sure that the spring pin hole in the shaft is aligned with the spring pin hole in the carrier. Install a new spring pin (6) through the carrier and in shaft (7) . Install spring pin (6) slightly below the outside surface of the carrier pin.

    6. Repeat Steps 25.a through 25.e for the remaining two planetary gears.

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Illustration 9	g00450668

26. Install Tooling (D) and a suitable lifting device (not shown) in order to planetary carrier assembly (5) .

27. Use the suitable device in order to install the planetary carrier assembly in the axle housing assembly. The weight of the planetary carrier assembly is approximately 80 kg (175 lb).

28. Use Tooling (C) in order to install retaining ring (3) on axle shaft (4) .

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Illustration 10	g00451163

29. Remove axle housing assembly (2) from Tooling (B) . Install the bottom half of the axle assembly on Tooling (B) in a vertical position.

30. Apply 1U-8846 RTV Silicone Sealant on the mating surfaces of the axle housing and of the differential housing.

31. Attach Tooling (A) and a suitable hoist to the rim of the axle shaft. Carefully install the axle housing assembly. The weight of axle housing assembly (2) is approximately 365 kg (800 lb).

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Illustration 11	g00450664

32. Install bolts (1) that secure axle housing assembly (2) to the differential housing. The torque for bolts (1) is 300 ± 40 N·m (220 ± 30 lb ft).

End By:

1. Install the fixed axle. Refer to Disassembly and Assembly, "Fixed Axle (Front) - Remove and Install".
2. Install the oscillating axle. Refer to Disassembly and Assembly, "Oscillating Axle (Rear) - Remove and Install".