D8R Series II Track-Type Tractor Power Train Caterpillar

Assembly Procedure

Note: O-ring seals, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring seal. A reconditioning procedure should not be degraded because of a low cost component such as an O-ring seal or a gasket. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.

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Illustration 1	g00619498

1. Install retaining ring (64) and spacer (66) in brake housing (39).

2. Lower the temperature of bearing cups (63) and (65).

3. Install the bearing cups in brake housing (39).
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   Illustration 2	g00619496

   Note: If bearing cone (62) was removed from housing (38), a new bearing must be installed.

4. Heat bearing cone (62) to a maximum temperature of 135 °C (275 °F).

5. Install bearing cone (62) on housing (38). Make sure that bearing cone (62) is seated on housing (38).
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   Illustration 3	g00619518

   Note: The brake housing weighs 150 kg (335 lb).

6. Use a hoist and tool (D) to position brake housing (39) on housing (38).

7. Heat bearing cone (61) to a temperature of 135 °C (275 °F).

8. Install bearing cone (61) on housing (38).

9. Install plate (49) and three bolts (46).

10. Install tool (G) on plate (49). Do not install the shims at this time.

11. Position brake housing (39) on wood blocks in order to raise housing (38) off the floor.
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    Illustration 4	g00619522

12. Use tool (G) to rotate housing (38).

13. Use tool (F) to measure the bearing preload. Tighten three bolts (46) equally until the proper preload is reached. The bearing preload should be 3 ± 1 N·m (28 ± 8 lb in).
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    Illustration 5	g00619526

14. When the bearing preload is correct, use a feeler gauge to measure the gap between the housing and plate (49) in three places. Average the three measurements in order to determine the correct shim pack thickness.

15. Remove three bolts (46) and plate (49).

16. Position the correct shim pack and plate (49) on the housing.

17. Install three bolts and washers (46).

18. Tighten three bolts to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

19. Use tool (G) to recheck the bearing preload.

20. Install the three remaining bolts and washers (46).

21. Tighten the three remaining bolts (46) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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    Illustration 6	g00619494

22. Install shuttle valve (67) and O-ring seal (59) in the brake housing.
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    Illustration 7	g00619534

23. Position ring (55) and spring (56) in brake housing (39).

24. Install ring (60) on piston (57).

25. Install seal ring (58) in piston (57). See Illustration 7. Apply clean oil to the lip of the seal ring.

26. Install piston (57) in the brake housing.

27. Install seal ring (53) in retainer (50). See Illustration 7. Apply clean oil to the lip of the seal ring.

28. Position retainer (50) on piston (57). Align the oil passage in retainer (50) with the oil passage and O-ring seal (59) in the brake housing.

29. Install six bolts and washers (45).

30. Position thrust washer (54) on retainer (50).

31. Install four friction discs (43) and the three brake plates. Alternate the friction discs and the brake plates.

32. Install ring (44) in hub (48).

33. Position hub (48), thrust washer (51), and retainer (52).

34. Install three bolts and washers (42).
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    Illustration 8	g00619491

    Note: Brake housing (39) weighs 150 kg (335 lb).

35. Use a hoist and tool (D) to position brake housing (39) on final drive housing (41).

36. Install two bolts and washers (40).
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    Illustration 9	g00619490

37. Position gear (37) on housing (38).

38. Install eighteen bolts and washers (36).
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    Illustration 10	g00619489

39. Position shim pack (35) and support bracket (34) on the brake housing.

40. Install twelve bolts and washers (33).
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    Illustration 11	g00619488

41. Lower the temperature of bearing cups (32).

42. Install bearing cups (32) in carrier (29).
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    Illustration 12	g00619537

43. Heat two bearing cones (30) to a maximum temperature of 135 °C (275 °F).

44. Install one bearing cone (30) on pinion (24).

45. Position carrier (29) on pinion (24).

46. Install remaining bearing cone (30) on pinion (24).
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    Illustration 13	g00622039

47. Install washer (25), lock washer (26), and nut (28) on the pinion (24). Install the large chamfered end of nut (28) toward the lock washer (26).

48. Position pinion (24) in a soft jawed vise.

49. Use tool (C) to tighten nut (28) and preload the bearings.
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    Illustration 14	g00622040

50. Position carrier (29) on two wood blocks.

51. Use tool (F) to measure the bearing preload. The correct bearing preload is 0.80 ± 0.50 N·m (7.0 ± 4.5 lb in).

52. Bend a tang of lock washer (26) in one of the four slots in nut (28).
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    Illustration 15	g00622041

53. Position the pinion and carrier (29) on support bracket (34).

54. Install the bolt and the washer (27).
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    Illustration 16	g00622042

55. Use tool (H) to check the backlash of pinion (24). Measure the backlash at three equally spaced teeth on pinion (24). Average the three measurements. The correct backlash is 0.210 ± 0.075 mm (0.0083 ± 0.0030 inch). If necessary, remove support bracket (34) in order to add or remove shims from shim pack (35).
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    Illustration 17	g00622052

56. Install bearing (22) in planetary gear (21).
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    Illustration 18	g00622053

57. Position planetary gear (21) and discs (23) in planetary carrier (15).

58. Install shaft (19) in planetary carrier (15).

59. If the rubber in pin (20) is damaged, replace the pin.

60. Align the hole in shaft (19) with the hole in planetary carrier (15).

61. Install pin (20). Install the pin so that the end of the pin is even with the surface of planetary carrier (15).

62. Repeat Steps 56 through 61 for the two remaining planetary gears.

63. Install the retaining ring in planetary carrier (15).

64. Use tool (B) to compress the retaining ring.

65. Slide planetary carrier (15) in ring gear (6).

66. Remove tool (B).
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    Illustration 19	g00622054

67. Position gear (18) and plate (17) on the carrier.

68. Install three bolts (16).
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    Illustration 20	g00622055

69. Install sun gear (14) in planetary carrier (15).
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    Illustration 21	g00622061

70. Install bearing (12) in planetary gear (11).
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    Illustration 22	g00622064

71. Position gear (11) and discs (13) in planetary carrier (7).

72. Install shaft (8).

73. If the rubber in pin (10) is damaged, replace the pin.

74. Align the hole in shaft (8) with the hole in planetary carrier (7).

75. Install pin (10) until the end of the pin is even with the surface of the carrier.

76. Repeat Steps 70 through 75 for the three remaining planetary gears.

77. Install seal ring (9) on planetary carrier (7).
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    Illustration 23	g00622066

78. Install planetary carrier (7) in ring gear (6).

79. Install the thrust ring and retaining ring (5).

80. Apply 6V-6640 Sealant to the flange of slinger (4). Position slinger (4) on the planetary carrier.

81. Install two bolts (2).
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    Illustration 24	g00622067

    Note: The carrier assembly weighs 48 kg (105 lb).

82. Install a hoist and tool (A).

83. Position sliding carrier (3) in the housing.

84. Remove tool (A).
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    Illustration 25	g00622069

85. Install two remaining bolts (2).

86. Install three equally spaced bolts and washers (1).

End By:

1. Install the left hand final drive, the steering differential, and the brake. Refer to Disassembly and Assembly, "Final Drive, Steering Differential, and Brake (Left Side) - Install" in this module.