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CX35 On-Highway Transmission Caterpillar


Transmission Planetary - Assemble

Usage:

CX35 W3X

Assembly Procedure

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Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1P-1863     Retaining Ring Pliers     1    
B     9U-7479     Compressing Tube     1    
C     2P-8312     Retaining Ring Pliers     1    
D     1U-9889     Crossblock     1    
1B-3573 Bolt     2    
8T-4994 Hard Washer     2    
8T-4122 Hard Washer     2    
8T-4223 Hard Washer     2    
6V-8188 Nut     2    
G     1P-0520     Driver Gp     1    
H     138-7575     Link Bracket     3    
J     1U-9200     Lever Puller Hoist     1    
K     138-7573     Link Bracket     2    
L     1P-2420     Transmission Repair Stand     1    
M     1P-1861     Retaining Ring Pliers     1    
P     -     1/2 - 13 by 11 in Threaded Rod     2    
6V-8188 Nut     4    
5F-7344 Puller Block     2    
R     1P-1863     Retaining Ring Pliers As     1    
T     9S-3263     Thread Lock Compound     1    
V     1P-0520     Driver Gp     1    

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.

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

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

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    Illustration 1g01354748

  1. Install seals (151) and (150) to piston (149) .
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    Illustration 2g01354303

  1. Install Tooling (P) in order to support piston (149) and spring (148) . Install piston (149) and spring (148) .
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    Illustration 3g01354818

  1. Lower the temperature of bearing (147) . Use Tooling (G) in order to install bearing (147) into planetary assembly (138) .
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    Illustration 4g01354287

  1. Position bearings (145) , thrust discs (144) , and gear (146) into planetary assembly (138) . Install shaft (142) and pin (143) . Repeat for the remaining planetary gears.
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    Illustration 5g01354184
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    Illustration 6g01354182

  1. Compress lock ring (141) and position ring gear (140) to planetary assembly (138) . Release the compressed lock ring (141) in order to secure ring gear (139) .

  1. Reposition planetary assembly (138) and install ring gear (139) .
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    Illustration 7g01354743
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    Illustration 8g01354121

  1. Attach Tooling (K) and a suitable lifting device to assembly (138) . The weight of planetary assembly (138) is approximately 45 kg (100 lb). Use Tooling (K) and the suitable lifting device in order to install planetary assembly (138) to the transmission housing.
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    Illustration 9g01354139

  1. Install plate (137) . Install discs and plates (136) . Install springs (135) , pins (134) , and plate (133) .
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    Illustration 10g01354852

  1. Install seals (131) and (132) to piston (127) .
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    Illustration 11g01354078

  1. Install O-ring seal (130) . Position manifold assembly (129) . Install bolts (128) . Tighten bolts (128) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

  1. Install piston (127) and spring (126) .
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    Illustration 12g01354021

  1. Compress lock ring (124) and position ring gear (125) . Release the compressed lock ring (124) in order to secure ring gear (125) .
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    Illustration 13g01353915

  1. Install plate (123) . Install discs and plates (122) . Install springs (121) , pins (120) , and plate (119) . Position clutch plate (118) and install bolts (117) . Tighten bolts (117) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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    Illustration 14g01353906

  1. Use Tooling (M) in order to install retaining ring (116) to planetary assembly (106) .

  1. Position bearings (114) , thrust discs (113) , and gear (115) into planetary assembly (106) . Install shaft (111) and pin (112) . Repeat for the remaining planetary gears.
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    Illustration 15g01353894

  1. Install bearing (109) and seal rings (110) to assembly (106) . Compress lock ring (108) and position ring gear (107) to planetary assembly (106) . Release the compressed lock ring (108) in order to secure ring gear (107) .
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    Illustration 16g01353779

  1. Attach Tooling (K) and a suitable lifting device to planetary assembly (106) . The weight of planetary assembly (106) is approximately 36 kg (80 lb). Use Tooling (K) and the suitable lifting device in order to position planetary assembly (106) to the transmission housing.
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    Illustration 17g01353772

  1. Position sun gear (104) onto shaft assembly (102) . Use Tooling (R) in order to install retaining ring (105) .
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    Illustration 18g01353765

  1. Install thrust bearing (103) . Install shaft assembly (102) .
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    Illustration 19g01353641

  1. Install thrust bearing (101) and plate (100) . Install discs and plates (99) . Install pins (98) , springs (97) , and plate (96) .
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    Illustration 20g01354940

  1. Lower the temperature of bearing cup (95) and raise the temperature of housing (75) . Use Tooling (G) and a suitable press in order to install bearing cup (95) .
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    Illustration 21g01354951

  1. Install retaining ring (94) .
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    Illustration 22g01353617

  1. Raise the temperature of bearing cone (86) and install bearing cone (86) .

  1. Install bearing (93) into shaft (87) . Install shaft (84) .

  1. Position bearing (91) , thrust discs (90) , and gear (92) into planetary assembly (84) . Install shaft (88) and pin (89) . Repeat for the remaining planetary gears.
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    Illustration 23g01354960

  1. Install the bearing spacer onto planetary assembly (84) . Position housing assembly (75) onto planetary assembly (84) .

  1. Raise the temperature of bearing cone (85) .

  1. Install bearing cone (85) and output rotor (83) . Use Tooling (V) to install lip seal (82) .

    Note: Lubricate the sealing lip of lip seal (82) .

    Note: Note the orientation of output rotor (83) .

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    Illustration 24g01355111

  1. Install seals (81) and (80) to piston (77) .
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    Illustration 25g01371027

  1. Install O-ring seal (78) and O-ring seals (79) .
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    Illustration 26g01371029

  1. Install piston (77) and spring (76) to housing assembly (75) .
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    Illustration 27g01353603

  1. Attach Tooling (H) and a suitable lifting device to housing assembly (75) . The weight of housing assembly (75) is approximately 43 kg (95 lb).

  1. Install bolts (74) . Tighten bolts (74) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).

  1. Install the O-ring seals and speed sensors (72) . Install bolts (73) . Tighten bolts (73) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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    Illustration 28g01353583

  1. Position housing assembly (70) and the O-ring seals. Install five bolts (67) (not shown). Tighten bolts (67) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).

  1. Install yoke (69) and the retainer. Apply Tooling (T) to bolt (68) . Install bolt (68) . Tighten bolt (68) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

  1. Connect harness assembly (71) and install the mounting hardware.
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    Illustration 29g01353576
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    Illustration 30g01353571

  1. Use Tooling (K) , Tooling (J) , Tooling (H) , and a suitable lifting device in order to reposition the transmission. The weight of the transmission is approximately 302 kg (665 lb). Position the transmission on Tooling (L) .
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    Illustration 31g01353170

  1. Remove Tooling (P) .
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    Illustration 32g01355183

  1. Install seals (65) and (66) to piston (63) .
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    Illustration 33g01353158

  1. Install piston (63) and spring (62) . Install O-ring seals (64) .
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    Illustration 34g01355204

    Dimension (X) equals 0.25 ± 0.13 mm (0.010 ± 0.005 inch).

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    Illustration 35g01353046

  1. Lower the temperature of bearing (56) in order to install bearing (56) . Use Tooling (G) in order to install bearing (56) to a depth of 0.25 ± 0.13 mm (0.010 ± 0.005 inch).

  1. Position bearings (60) , thrust discs (59) , and gear (61) . Install shaft (57) and pin (58) . Repeat for the remaining planetary gears.
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    Illustration 36g01353015

  1. Position sun gear (55) and install retaining ring (54) . Install retaining ring (53) . Compress retaining ring (53) in order to install ring gear (52) .
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    Illustration 37g01352981

  1. Install thrust bearing (51) .

    Note: Be sure to orient thrust bearing (51) correctly.

  1. Use two people in order to install planetary assembly (50) . The weight of planetary assembly (50) is approximately 30 kg (65 lb).
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    Illustration 38g01352957

  1. Install thrust disc (49) (not shown).

    Note: Be sure to orient thrust disc (49) correctly.

  1. Install thrust bearing (48) .

    Note: Be sure to orient thrust bearing (48) correctly.

  1. Install plate (47) . Install discs and plates (46) .

  1. Install springs (45) and pins (44) . Install plate (43) .
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    Illustration 39g01352953

  1. Install sun gear (42) and spring (41) .

  1. Position manifold assembly (40) and install bolts (39) . Tighten bolts (39) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
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    Illustration 40g01352951

  1. Install seal rings (38) .
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    Illustration 41g01352949

  1. Lower the temperature of bearing cup (37) in order to install bearing cup (37) .
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    Illustration 42g01355234

  1. Install carrier assembly (35) . Raise the temperature of bearing cone (36) . Install bearing cone (36) .

  1. Install seals (34) , (33) , and (32) .
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    Illustration 43g01352929

  1. Lower the temperature of bearing (30) . Install bearing (30) . Install the seal and O-ring seal (31) .
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    Illustration 44g01355240

  1. Install seal (29) to piston (28) .
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    Illustration 45g01352880

  1. Install piston (28) and spring (27) .
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    Illustration 46g01352874

  1. Use two people in order to position hub assembly (26) . The weight of hub assembly (26) is approximately 30 kg (65 lb). Install bolts (25) . Tighten bolts (25) to a torque of 12 ± 3 N·m (105 ± 27 lb in).
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    Illustration 47g01352868

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    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.

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  1. Use Tooling (D) in order to compress balance piston (23) . Use Tooling (C) in order to install retaining ring (24) .
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    Illustration 48g01352862

  1. Install clutch plates and discs (22) .
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    Illustration 49g01352855

  1. Install hub (21) and thrust disc (20) . Position plate (19) and retaining ring (18) .

  1. Compress retaining ring (18) in order to install plate (19) .
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    Illustration 50g01352848

  1. Install the seal ring and O-ring seal (17) . Install bearing (16) and thrust bearing (16A) .

    Note: Be sure to orient thrust bearing (16A) correctly.

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    Illustration 51g01355267

  1. Install seal (15) to piston (14) .
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    Illustration 52g01352841

  1. Install piston (14) .
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    Illustration 53g01352830
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    Illustration 54g01352832

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    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.

    ----------------------

  1. Position retainer (12) and spring (13) onto shaft assembly (10) .

  1. Position shaft assembly (10) in a suitable press. Use Tooling (B) and the suitable press in order to compress retainer (12) and spring (13) . Use Tooling (C) in order to install retaining ring (11) .
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    Illustration 55g01352827

  1. Install hub (8) . Use Tooling (A) in order to install retaining ring (7) . Install thrust disc (7A) .

  1. Install clutch discs and plates (9) .
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    Illustration 56g01352816

  1. Install plate (6) and retaining ring (5) to rotating clutch (3) .
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    Illustration 57g01352806

  1. Use two people in order to install rotating clutch (3) . The weight of rotating clutch (3) is approximately 29 kg (65 lb).

  1. Raise the temperature of bearing (4) . Install bearing (4) .
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    Illustration 58g01352804

  1. Install the gasket into the housing. Install bearing (1) and seal rings (2) .

End By: Connect the transmission to the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Connect".

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