966F Series II Wheel Loader Power Train Caterpillar

Assembly Procedure

1. Clean all parts of the differential. Inspect all parts of the differential. If any of the parts are worn or damaged, use new parts for replacement.

Show/hide table



Illustration 1	g00470331

2. Install thrust washer (17) in the case housing. Lubricate the face of the thrust washer with clean axle oil.

3. Replace the disc packs, if the stack heights of the disc packs are not symmetrical within 0.10 mm (0.004 inch).

4. Replace the disc packs, if the friction material is worn.

Show/hide table



Illustration 2	g00470333

5. Only replace the disc packs with disc packs of the same type. If the word "THIN"is marked on the cover, then replace the disc packs with two disc packs that are marked "THIN". If the word "THICK" is marked on the cover, then replace the disc packs with two new disc packs that are marked "THICK". Do not interchange the disc packs. Use two "THIN" or two "THICK". Do not use thin discs and thick discs at the same time..

   Note: Lubricate the plates and the friction discs prior to assembly. Use clean axle oil to thoroughly lubricate the plates and the friction discs.

Show/hide table



Illustration 3	g00469857

Show/hide table



Illustration 4	g00469856

6. Install two new friction discs (16) and two plates (15) in alternate order in the case housing. Start with a plate and end with a friction disc, as shown.

Show/hide table



Illustration 5	g00469827

Show/hide table



Illustration 6	g00470405

7. Align the keys of actuator housing (14) with the slots of the case housing. Install actuator housing (14), as shown.

Show/hide table



Illustration 7	g00469825

8. Install gear (13) in the case housing. The gear must be fully seated.

   Note: Turn the gear slowly until the spline engages with the two friction discs that were installed in Step 6.

Show/hide table



Illustration 8	g00469822

9. Install two pinion gears (9) on pinion shaft (10). Repeat for the remaining pinion shaft (12) and two pinion gears (11). Lubricate the pinion gears and pinion shafts with clean axle oil.

Show/hide table



Illustration 9	g00469819

10. Install pinion shaft (12) and two pinion gears (11) in the case housing, as shown.

11. Rotate pinion gears (11) slightly until the pinion shaft rests in the slots of the actuator housing.

Show/hide table



Illustration 10	g00469818

12. Install the remaining pinion shaft (10) and two pinion gears (9), as shown.

Show/hide table



Illustration 11	g00470451

Show/hide table



Illustration 12	g00469815

13. Assemble gear (8) and actuator housing (7) on a bench, as shown. Align the keys of actuator housing (7) with the slots of the case housing. Install the actuator housing, as shown.

    Note: Lubricate the plates and the friction discs prior to assembly. Use clean axle oil to thoroughly lubricate the plates and the friction discs.

Show/hide table



Illustration 13	g00469814

Show/hide table



Illustration 14	g00469811

14. Install two friction discs (5) and two plates (6) in alternate order in the case housing. Start with a friction disc and end with a plate.

    Note: Steps 15 through 23 describe the procedure for measuring the end play gap.

Show/hide table



Illustration 15	g00469747

15. Install Tooling (A) on the differential assembly, as shown.

    Note: The center bolt of Tooling (A) must have M16 X 2.0 thread. This will allow the center bolt to apply the proper preload on the disc packs.

Show/hide table



Illustration 16	g00469748

16. Tighten the center bolt of Tooling (A) to a torque of 27 N·m (20 lb ft). This will apply 900 kg (2000 lb) of preload on the disc packs.

Show/hide table



Illustration 17	g00469751

17. Mount the magnetic base of Tooling (B) on face (A) of cover (2) .

18. Zero the dial indicator on Face (B), as shown.

Show/hide table



Illustration 18	g00469767

19. Carefully remove Tooling (B) from the cover.

20. Mount the magnetic base of Tooling (B) on Face (C) of the differential housing. Touch the dial indicator of Tooling (B) on the disc pack of Face (D) .

21. Record the indicator reading.

22. Record two additional indicator readings from separate areas of Face (D) .

23. Average the three indicator readings. This is the measured end play gap.

    Note: If the existing disc packs were installed in Step 5, continue with Step 25.

24. If the end play gap in Step 23 was greater than 0.81 mm (0.032 inch), replacement of the existing disc pack is necessary.

    Note: Follow steps 25 through 30 for replacement of the disc packs.

25. Only replace the disc packs with disc packs of the same type. If the word "THIN" is marked on the cover, then replace the disc packs with two disc packs that are marked "THIN". If the word "THICK" is marked on the cover, then replace the disc packs with two new disc packs that are marked "THICK". Do not interchange the disc packs. Use two "THIN" or two "THICK". Do not use a thin disc and a thick disc together..

26. Install the new disc packs in the limited slip differential. Measure the end play gap. Steps 15 through 23 describe the proper procedure for measuring the end play gap. The measured end play gap must be between 0.203 mm (0.0080 inch) and 0.508 mm (0.0200 inch).

27. If the measured end play gap is greater than 0.508 mm (0.0200 inch) and two "THIN"disc packs were installed, remove the two "THIN" disc packs and install two "THICK"disc packs. Measure the end play gap again. The measured end play gap must be between 0.203 mm (0.0080 inch) and 0.508 mm (0.0200 inch).

28. Replacement of the pinion shafts or the actuator housings may be required in order to achieve the proper end play gap. Install either two "THIN"or two "THICK"disc packs, as required. The measured end play gap must be between 0.203 mm (0.0080 inch) and 0.508 mm (0.0200 inch).

Show/hide table



Illustration 19	g00470997

29. If the disc packs were changed from the kind that was marked on the outside of the cover, replace the existing mark with either "THICK"or "THIN"for future reference.

Show/hide table



Illustration 20	g00469667

30. Install thrust washer (4) in cover (2). Lubricate the face of the thrust washer with clean axle oil.

    Note: Apply a small amount of grease to the back side of the thrust washer prior to installing. This will retain the thrust washer in place when the cover is installed.

Show/hide table

NOTICE
A new differential group or a new case assembly will be equipped with bolts that are used for shipping, assembly, and storage purposes only. Remove and discard these bolts after the bevel gear has been installed. These bolts should not be used for final assembly.

Show/hide table



Illustration 21	g00470333

Show/hide table



Illustration 22	g00469567

31. Align the stamped marks of the case housing with the stamped marks of the cover. Install cover (2) on case housing (3) .

32. Install bolts (1) in order to hold the two halves of the differential case together. Tighten bolts (1) to a torque of 61 ± 7 N·m (45 ± 5 lb ft). Bolts (1) are used to hold the differential case together until final assembly. Remove bolts (1) and discard bolts (1) after the bevel gear has been installed.

End By: Install the differential. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Remove and Install".