844K Wheel Dozer and 990K Wheel Loader Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, thoroughly all parts in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Note: Apply oil to all the bearings before assembly.

1. Check the condition of the O-ring seals that are used in the torque converter and torque converter housing. If any of the seals are damaged, use new parts for replacement.
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   Illustration 1	g06020183

2. Install bolts (82) in cover (83). Tighten bolts (82) to a torque of 60 ± 7 N·m (45 ± 5 lb ft).

3. Install O-ring seal (81).

4. Install plugs (80) into housing assembly (26). Tighten plugs (80) to a torque of 50 ± 5 N·m (37 ±4 lb ft).
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   Illustration 2	g06020211

5. Turn over housing assembly (26). Place the housing assembly on suitable blocking.

6. Install O-ring seals (79) to clutch piston (78).

7. Install clutch piston (78) to housing assembly (26).
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   Illustration 3	g06020173

8. Install sleeve bearing (77) into housing assembly (26).

9. Install clutch discs and clutch plates (76) in an alternating order.

   Note: Start with a clutch disc and end with a clutch disc.

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   Illustration 4	g06020168

10. Install clutch plate (75) into the housing assembly.

11. Install retaining ring (74) in the housing assembly.
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    Illustration 5	g06020166

12. Install bearing (72), race (73), and retainer (71) in the housing assembly.
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    Illustration 6	g06020162

13. Install the converter turbine (69) on clutch adapter (70).
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    Illustration 7	g06020160

14. Install the race to the back of turbine hub (68).

15. Install bolts (67) to install turbine hub (68) to converter turbine (69). Tighten bolts (67) to a torque of 105 ± 15 N·m (80 ± 10 lb ft).
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    Illustration 8	g06020154

16. Install converter turbine assembly (66) into housing assembly (26).
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    Illustration 9	g06020151

17. Install bearing (64), race (65), and retainer (63) into housing assembly.
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    Illustration 10	g06020069

18. Install orifice plug (62) into stator carrier (18).
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    Illustration 11	g06020068

19. Raise the temperature of seal ring carrier (61) to a maximum temperature of 135 °C (275 °F).

    Note: Note the location of the two holes in the side of seal ring carrier (61). Make sure that one hole is aligned with the oil passage on stator carrier (18). Make sure that the remaining hole is in alignment with the hole that is provided for the installation of dowel pin (59). Failure to align the oil passages in seal ring carrier (61) and stator carrier (18) will result in failure of the components.

20. Install seal ring carrier (61) onto stator carrier (18).

21. Install dowel pin (59) into seal ring carrier (61).

22. Install seal rings (60) to seal ring carrier (61).
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    Illustration 12	g06020216

23. Raise the temperature of inner bearing (57) to a maximum temperature of 135 °C (275 °F).

24. Install inner bearing (57) onto stator carrier (18).

25. Install O-ring seal (58) on the stator carrier.
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    Illustration 13	g06020060

26. Lower the temperature of race (56).

27. Install race (56) into housing (25).

28. Install drive gear (55) and bolts (54) into housing (25). Tighten bolts (54) to a torque of 60 ± 7 N·m (45 ± 5 lb ft).
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    Illustration 14	g06020052

29. Use Tooling (B) and a suitable lifting device to install housing (25) onto stator carrier (18).
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    Illustration 15	g06020050

30. Install O-ring seals (53) to housing (25).

31. Install Remove bearing (51), race (52) , and retainer (50) onto the stator carrier.
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    Illustration 16	g06020041

32. Install lockup clutch piston (49).
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    Illustration 17	g06020037

33. Install clutch discs and clutch plates (48) in an alternating order.

    Note: Start with a clutch disc and end with a clutch disc.

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    Illustration 18	g06020034

34. Install clutch plate (47).
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    Illustration 19	g06020032

35. Install seal ring (46) onto stator carrier (18).
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    Illustration 20	g06020030

36. Install dowel pins (44), sleeve bearing (45) to clutch adapter assembly (43).
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    Illustration 21	g06020027

37. Install impeller (41) to clutch adapter assembly (43).
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    Illustration 22	g06020025

38. Install race (42) on the back of hub (39).
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    Illustration 23	g06020022

39. Install hub (39) and bolts (40) to impeller (41). Tighten bolts (40) to a torque of 105 ± 15 N·m (80 ± 10 lb ft).
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    Illustration 24	g06020020

40. Install bearing, (37), race (38), and retainer (36).
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    Illustration 25	g06020016

41. Install impeller hub (35) onto stator carrier (18).
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    Illustration 26	g06020015

42. Install retaining ring (34) to stator carrier (18).
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    Illustration 27	g06019971

43. Install retaining ring (29), plate (30), retaining ring (31), retaining ring (33), and splined adapter (32) to the stator.
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    Illustration 28	g06019942

44. Install stator (28).
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    Illustration 29	g06019939

45. Install retaining ring (27) to stator carrier (18).
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    Illustration 30	g06019925

46. Turn over housing assembly (25). Place the housing onto suitable blocking.

47. Use Tooling (B) and a suitable lifting device to install housing assembly (25) into housing (26). The weight of housing (24) and the components is approximately 133 kg (295 lb). The weight of housing assembly (26) and the components is approximately 68 kg (150 lb).
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    Illustration 31	g06019924

48. Install bolts (24) into the housing assembly. Tighten bolts (24) to a torque of 60 ± 7 N·m (45 ± 5 lb ft).
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    Illustration 32	g06019922

49. Install ring (23) to shaft (19).
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    Illustration 33	g06020232

50. Raise the temperature of carrier (21) and bearing (20) to a temperature of 149 °C (300 °F).

51. Install the seal carrier and the bearing onto shaft (19).

52. Install rings (22) onto carrier (21).
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    Illustration 34	g06019882

53. Use Tooling (A) and a suitable lifting device to install shaft (19) into the torque converter.
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    Illustration 35	g06019879

54. Lubricate the bore of the O-ring seal lightly with the lubricant that being sealed.

55. Install O-ring seal (17) on stator carrier (18).
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    Illustration 36	g06019878

56. Lubricate the sealing lip lightly with the lubricant that being sealed.

57. Install lip seal (15) in retainer (16).
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    Illustration 37	g06019877

58. Install the gasket and retainer (15).

59. Install bolts (14). Tighten bolts (14) to a torque of 60 ± 7 N·m (45 ± 5 lb ft).
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    Illustration 38	g06019876

60. Install O-ring seal (13) into yoke (11).

    Note: Apply Tooling (E) to the O-ring seal to hold the O-ring seal in place during assembly.

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    Illustration 39	g06019874

61. Install yoke (11) and retainer (12).

62. Install bolt (10) on shaft (19). Tighten bolt (10) to a torque of 240 ± 25 N·m (175 ± 20 lb ft).
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    Illustration 40	g06019868

63. Install dowel pins (9) into housing assembly (3).

64. Use Tooling (B) and a suitable lifting device to install housing assembly (3) onto the torque converter assembly. The weight of housing assembly (3) is approximately 110 kg (243 lb).
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    Illustration 41	g06019869

65. Install bolts (8) in the housing assembly.
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    Illustration 42	g06019864

66. Lubricate the bore of the O-ring seal lightly with the lubricant that being sealed.

67. Install O-ring seal (5), sleeve (6), and O-ring seal (7) into housing assembly (3).
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    Illustration 43	g06019862

68. Install O-ring seals (4) in housing (1).

    Note: Apply Tooling (E) on the O-ring seals to hold the O-ring seals in place during the assembly.

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    Illustration 44	g06019861

69. Install housing (1) onto housing assembly (3).

70. Install bolts (2).

End by:

a. Install the torque converter.