854K Wheel Dozer and 992K Wheel Loader Power Train Caterpillar

Assembly Procedure

Note: Check the O-ring seals and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 1	g00396218

1. Install O-ring seals (133) on bearing cage (128). Use a suitable hammer in order to tap bearing (132) into bearing cage (128).
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   Illustration 2	g00396197

2. Install retaining ring (131) in bearing cage (128).
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   Illustration 3	g01443314

3. Install bearing cage (128) into housing assembly (125). Install bolts (127) in bearing cage (128).

4. Install dowel (129) and plug (130) into housing assembly (125).
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   Illustration 4	g00395719

5. Install dowels (126) into housing assembly (125).
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   Illustration 5	g00395621

6. Install O-ring seals (124) on housing assembly (125).
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   Illustration 6	g00395618

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   Illustration 7	g00395617

7. Apply clean oil to roller bearing (123). Install roller bearing (123) in planetary gear (122). Install one thrust disc (121) on each side of the planetary gear, as shown.

8. Install thrust discs (121) and planetary gear (122) into planetary carrier (95 ). Install planetary shaft assembly (120). Make sure that the spring pin hole in planetary shaft (120) is aligned with the spring pin hole in planetary carrier (95 ). Install spring pin (119) that holds planetary shaft assembly (120) in position. Make sure that spring pin (119) is flush with the outside surface of planetary carrier (95 ).

9. Repeat Steps 7 and 8 for the remaining planetary gears (122).
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   Illustration 8	g01443335

10. Position planetary carrier (95) onto suitable cribbing, as shown. Use Tooling (F) in order to install bearing (118) into planetary carrier (95).
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    Illustration 9	g01445422

11. Use Tooling (H) in order to install retaining ring (117) into planetary carrier (95).
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    Illustration 10	g01443337

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    Illustration 11	g01443342

12. Use Tooling (F) in order to install a bearing sleeve (115) in each end of output shaft assembly (112). Install bearing sleeves (115) to the depth that is shown in Illustration 11. The weight of output shaft assembly (112) is approximately 27 kg (60 lb).

13. Install dowel (116) into output shaft assembly (112). Install dowel (116) to the dimension that is shown in Illustration 11.
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    Illustration 12	g00395480

14. Install hub (114) onto output shaft assembly (112). The weight of hub (114) is approximately 20 kg (45 lb).
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    Illustration 13	g00395479

15. Install sun gear (113) on output shaft assembly (112).
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    Illustration 14	g01443395

16. Use Tooling (D) and a suitable lifting device in order to install planetary carrier (95) onto output shaft assembly (112). The weight of planetary carrier (95) is approximately 52 kg (115 lb).

    Note: Make sure that the slot in bearing (118) aligns with the dowel in output shaft assembly (112).

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    Illustration 15	g00395339

17. Install ring seal (111) onto sun gear (109).
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    Illustration 16	g01445442

18. Install sun gear (109) on the output shaft. Use Tooling (D) in order to install retaining ring (110) onto the output shaft.
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    Illustration 17	g00395299

19. Reposition the assembly onto the opposite side. Apply clean oil to clutch discs (107) and on clutch plates (108). Install clutch discs (107) and clutch plates (108) in alternating order. Start with a clutch disc (107).
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    Illustration 18	g00395218

20. Install pins (105) and springs (106) with the pins.
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    Illustration 19	g01443182

21. Raise the temperature of ring (102) to a maximum temperature of 120°C (248°F) to 148 °C (298 °F) for a maximum of 10 minutes. Install ring (102) onto clutch housing (97). Make sure that the part number for ring (102) is facing upward.

22. Install seal rings (104) onto ring (102). Install spring pin (103) and dowel (103A) into clutch housing (97).
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    Illustration 20	g00395197

23. Install plugs (100) and dowels (101) into clutch housing (97).
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    Illustration 21	g00395028

24. Apply clean oil to seal rings (99). Install seal rings (99) onto clutch piston (98) so that the oil grooves are facing toward the inside of the clutch housing.
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    Illustration 22	g00395024

25. Install clutch piston (98) into clutch housing (97). The weight of clutch housing (97) is approximately 41 kg (90 lb).
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    Illustration 23	g01443161

26. Use Tooling (G) in order to hold clutch piston (98) in clutch housing (97). Use Tooling (D) in order to install clutch housing (97) and clutch piston (98). The combined weight of clutch housing (97) and of clutch piston (98) is approximately 61 kg (135 lb).
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    Illustration 24	g00395018

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

27. Install the washers and bolts (96) into clutch housing (97). Tighten bolts (96) to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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    Illustration 25	g01443131

28. Use Tooling (D) and a suitable lifting device in order to install planetary carrier (95) and the connected components. The combined weight of carrier (95) and of the components is approximately 186 kg (410 lb).
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    Illustration 26	g01443127

29. Install retaining ring (94).
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    Illustration 27	g00393997

30. Apply clean oil to seal rings (93). Install seal rings (93) onto clutch piston (91) so that the oil groove is facing toward the inside of the clutch housing.
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    Illustration 28	g00393977

31. Install clutch piston (91) into clutch housing (92). The weight of clutch housing (92) is approximately 41 kg (90 lb).
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    Illustration 29	g01443114

32. Attach Tooling (B) and a suitable lifting device to clutch housing (92). Use Tooling (B) and the suitable lifting device in order to install clutch piston (91) and clutch housing (92) as a unit. The combined weight of the clutch piston (91) and of clutch housing (92) is approximately 54 kg (120 lb).
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    Illustration 30	g00393925

33. Install ring gear (90).
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    Illustration 31	g00393924

34. Install springs (87). Apply clean oil to clutch discs (88) and clutch plates (89). Install clutch discs (88) and clutch plates (89) in alternating order. Start with a clutch disc (88).
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    Illustration 32	g00393923

35. Apply clean oil to seal ring (86). Install dowel (85), ring (84), and metal ring seal (86) onto input shaft (27).
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    Illustration 33	g00393921

36. Use two people in order to install input shaft (27). The weight of input shaft (27) is approximately 32 kg (70 lb).
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    Illustration 34	g01445384

37. Install dowels (83) into clutch housing (81). Two of dowels (83) are located on the bottom of clutch housing (81). The weight of clutch housing (81) is approximately 56 kg (124 lb).
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    Illustration 35	g00393919

38. Apply clean oil to seal rings (82). Install seal rings (82) onto clutch piston (80) so that the oil groove is facing toward the inside of the clutch housing.
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    Illustration 36	g00393918

39. Install clutch piston (80) into clutch housing (81). The weight of clutch housing (81) is approximately 64 kg (140 lb).
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    Illustration 37	g01443099

40. Attach Tooling (B) and a suitable lifting device onto clutch housing (81). Use Tooling (B) and the suitable lifting device in order to install clutch piston (80) and clutch housing (81) as a unit. The combined weight of clutch piston (80) and of clutch housing (81) is approximately 86 kg (190 lb).
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    Illustration 38	g00393831

41. Install ring gear (79). Install lock plates (78), locks (77), and bolts (76) in order to secure ring gear (79).
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    Illustration 39	g00393830

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    Illustration 40	g01445448

42. Apply clean oil to bearing assemblies (75). Install bearing assemblies (75) in planetary gears (74). Install one thrust disc (73) on each side of each planetary gear (74).

43. Install thrust discs (73) and planetary gears (74) into planetary carrier (70). Install planetary shaft (72). Make sure that the spring pin hole in planetary shaft (72) is aligned with the spring pin hole in planetary carrier (70). Install spring pin (71) into planetary shaft (72) so that spring pin (71) is flush with the outside surface of planetary carrier (70).

44. Repeat Steps 42 and 43 for the remaining planetary gears (74).
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    Illustration 41	g01443072

45. Use Tooling (D) and a suitable lifting device in order to install planetary carrier (70). The weight of planetary carrier (70) is approximately 59 kg (130 lb).
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    Illustration 42	g01445379

46. Install pins (66) and springs (67).

47. Apply clean oil to clutch discs (68) and on clutch plates (69). Install clutch discs (68) and clutch plates (69) in alternating order. Start with a clutch disc (68).
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    Illustration 43	g00393825

48. Apply clean oil to seal rings (65). Install seal rings (65) onto clutch piston (63) so that the oil grooves are facing toward the inside of the clutch housing.
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    Illustration 44	g00393824

49. Use two people in order to install clutch piston (63) into clutch housing (64). The weight of clutch piston (63) is approximately 23 kg (51 lb).
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    Illustration 45	g01443018

50. Attach Tooling (B) and a suitable lifting device to clutch housing (64). Use Tooling (B) and the suitable lifting device in order to install clutch piston (63) and clutch housing (64) as a unit. The combined weight of clutch piston (63) and clutch housing (64) is approximately 77 kg (170 lb).
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    Illustration 46	g00393761

51. Install ring gear (62).
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    Illustration 47	g00393760

52. Install retaining ring (61) onto coupling gear (60).
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    Illustration 48	g00393758

53. Install coupling gear (60).
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    Illustration 49	g01443511

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    Illustration 50	g00393661

54. Position bearing cage (55) onto suitable cribbing. Use Tooling (F) in order to install bearing (59), as shown.

55. Install retaining ring (58) in bearing cage (55).
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    Illustration 51	g00393660

56. Install dowel (57) in gear assembly (56).
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    Illustration 52	g00393659

57. Install gear assembly (56) in bearing cage (55).

    Note: Make sure that the dowel in gear assembly (56) aligns with the slot in the bearing cage.

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    Illustration 53	g00393658

58. Install bearing cage (55). Use locks (54) and bolts (53) in order to secure bearing cage (55).
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    Illustration 54	g00393657

59. Install pins (49) and springs (51).

60. Apply clean oil to clutch discs (50) and on clutch plates (52). Install clutch discs (50) and clutch plates (52) in alternating order. Start with a clutch disc (50).
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    Illustration 55	g00393379

61. Install dowels (48) into clutch housing (46). The weight of clutch housing (46) is approximately 55 kg (120 lb).
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    Illustration 56	g00393378

62. Apply clean oil to seal rings (47). Install seal rings (47) on clutch piston (45) so that the oil grooves are facing toward the inside of the clutch housing.
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    Illustration 57	g00393377

63. Install clutch piston (45) into clutch housing (46).
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    Illustration 58	g01442874

64. Attach Tooling (B) and a suitable lifting device to clutch housing (46). Use Tooling (B) and the suitable lifting device in order to install clutch piston (45) and clutch housing (46) as a unit. The combined weight of clutch piston (45) and clutch housing (46) is approximately 77 kg (170 lb).
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    Illustration 59	g00393337

65. Install seal ring (44) onto sun gear (43).
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    Illustration 60	g01442852

66. Install sun gear (43) onto input shaft (27).

    Note: Use the correct method in order to make the new rings ready for installation. Place your hands on each end of the ring and expand the ends by each other. Keep the ring in a circular shape in order to ensure an even bend fully around the ring. The notches in the ends of the rings must contact each other. The ring will damage the edge of the bore if the ring is not installed correctly. The notches must be fully engaged.

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    Illustration 61	g00397059
    Correct method for expanding the rings

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    Illustration 62	g00397061
    The ends of the ring must contact the inner notches (bottom half of the above illustration).

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    Illustration 63	g00397157
    Do not use this method to make new rings ready for installation.

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    Illustration 64	g01442847

67. Install metal seal rings (42) and (41) onto ring carrier (40).
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    Illustration 65	g01442843

68. Apply a small bead of Tooling (J) to the lower half of the inside surface of ring carrier (40).

69. Install ring carrier (40) onto input shaft (27).

70. Align the pin bores.

71. Install pin (39) into ring carrier (40). Recess pin (39) 3.5 ± 0.5 mm (0.14 ± 0.02 inch) into ring carrier (40).

72. Remove any excess compound from the assembly.
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    Illustration 66	g01442841

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    Illustration 67	g01442833

73. Apply clean oil to bearing assemblies (37). Install bearing assemblies (37) into planetary gear (38). Position one thrust disc (36) on each side of planetary gear (38).

74. Install thrust discs (36) and planetary gear (38) into carrier assembly (28). Install shaft assembly (35). Make sure that the spring pin hole in shaft assembly (35) is aligned with the spring pin hole in carrier assembly (28).

75. Install spring pin (34) so that the spring pin is 19.0 mm (0.75 inch) from the root of the gear on carrier assembly (28).

76. Repeat Steps 73 and 74 for the remaining planetary gears (38).

77. Install dowel (33) into carrier assembly (28).
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    Illustration 68	g01442826
    Typical Example

78. Install bearing (32) and retaining ring (31).
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    Illustration 69	g01442814
    Typical Example

79. Compress retainer ring (30) (not shown) and install coupling gear (29) onto carrier assembly (28).
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    Illustration 70	g01442795
    Typical Example

80. Use Tooling (C) and a suitable lifting device in order to install carrier assembly (28) and coupling gear (29). The combined weight of carrier assembly (28) and of coupling gear (29) is approximately 68 kg (150 lb).

    Note: Make sure that the slot in the bearing aligns with the dowel in the shaft.

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    Illustration 71	g01442792
    Typical Example

81. Install retaining ring (26) onto input shaft (27).
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    Illustration 72	g00675820

82. Install pins (23).

83. Apply clean oil to clutch discs (24) and on clutch plates (25). Install clutch discs (24) and clutch plates (25) in alternating order. Start with a clutch disc (24).
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    Illustration 73	g00675819

84. Install springs (22).
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    Illustration 74	g00393001

85. Install bearing (21) into end plate (20).
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    Illustration 75	g01442747

86. Use Tooling (B) and a suitable lifting device in order to install end plate (20). The weight of end plate (20) is approximately 57 kg (125 lb).

    Note: Make sure that the slot in the bearing aligns with the dowel in the carrier assembly.

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    Illustration 76	g00392876

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

87. Install the washers and bolts (19) in end plate (20). The torque for the bolts is 410 ± 50 N·m (302 ± 37 lb ft).

88. Install retaining ring (18) onto the carrier assembly.
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    Illustration 77	g00392874

89. Install pilot plate (17). Install the washers and bolts (16).
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    Illustration 78	g02547688

90. Use Tooling (B) and a suitable lifting device in order to install transmission case assembly (4) onto housing assembly (15). The weight of transmission case assembly (4) is approximately 211 kg (465 lb).

91. Install the washers and bolts (14) that secure transmission case assembly (4) to housing assembly (15).

92. Install the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Control Valve - Install".
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    Illustration 79	g01442686

93. Install O-ring seals (13) on each sleeve (11).
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    Illustration 80	g01442674

94. Install sleeves (11) into transmission hydraulic control valve (12). Install the retainer and bolt (10).
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    Illustration 81	g02547536

95. Install O-ring seals (9) and (8) into manifold (6).
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    Illustration 82	g02547497

96. Position manifold (6) and install bolts (5) onto transmission case assembly (4).

97. Install tube assembly (7).
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    Illustration 83	g02547376

98. Check the condition of the gasket that is used with cover (3). If the gasket is damaged, use a new part for replacement. Install bolts (1) and bolts (2) in order to secure the gasket and cover (3) to transmission case assembly (4).

End By:

1. Connect the input transfer gears and the output transfer gears to the transmission.