TA19 Transmission Caterpillar

Transmission - Assemble

Usage:

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Brackets	4
B	154-6182	Forcing Screws	2
C	1P-0520	Driver Gp	1
D	3E-3879	Eyebolt M16 x 2	1
	4C-8358	Eyebolt M10 x 1.5	1
	4C-8359	Eyebolt M12 x 1.75	1
E	154-6181	Forcing Screw	1
F	203-5581	Plate	1
G	FT-2769	Table	1
H	1P-2322	Combination Puller	1
H	8B-7560	Step Plate	1
J	5P-4758	Retaining Ring Pliers As	1
K	207-8153	Shaft Retainer	1
L	8T-5096	Dial Indicator Gp	1
M	1U-8846	Gasket Sealant	-
N	380-3894	Driver Pump Drive	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.

Note: Lubricate all seal rings and O-ring seals prior to assembly.

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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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Illustration 1	g01270596

Lower the temperature of bearing cups (144). Install bearing cups (144) .

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Illustration 2	g02517517
Cutaway view of case assembly (31) .

Lower the temperature of bearing cup (36) and install bearing cup (36) into case assembly (31) .

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Illustration 3	g01329472

Refer to Steps 26 through 29 in order to assemble clutch assembly (143) .

Use two people in order to install clutch assembly (143). The weight of clutch assembly (143) is approximately 25 kg (55 lb). Install bolts (142) .

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Illustration 4	g01270555
Input Shaft

Install bearings (141) and thrust washer (139) onto shaft assembly (128). Install gear (140), thrust washer (139), and spacer (138). Raise the temperature of bearing cone (137). Install bearing cone (137). Install the seal rings after installation of bearing cone (137) .
Note: The procedure for the assembly of the clutch packs will be identical.

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Illustration 5	g01270098

Install thrust washer (134) and bearings (136) onto shaft assembly (128). Install gear (135), thrust washer (134), and spacer (133) .

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Illustration 6	g01270092

Install gear (132), gear (131), spacer (130), and spacer (129) onto shaft assembly (128) .

Raise the temperature of bearing cone (127) and install bearing cone (127) onto shaft assembly (128) .

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Illustration 7	g01270078
Output Shaft

Install spacer (126) and bearing (125) onto shaft assembly (99). Install gear (124), thrust washer (123), tube (122), sun gear (121), and thrust washer (120) onto shaft assembly (99) .

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Illustration 8	g01269978

Install a new cap plug onto shaft (106)
Note: Procedure for assembly of planet carriers is identical.

Position bearings (103), gear (104), thrust disc (102), and shaft (106) onto carrier (101). Install shaft (106). Install pin (105) .

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Illustration 9	g01270067

Install planetary carrier (119) and spacer (118) onto shaft assembly (99). Raise the temperature of bearing cone (117). Install bearing cone (117) onto shaft assembly (99) .

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Illustration 10	g01280580

Install rotor (116) and bolts (115) onto shaft assembly (99) .

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Illustration 11	g01269983

Install bearing (112) onto shaft assembly (99). Install gear (111), thrust washer (110), spacer (109), sun gear (108), and thrust washer (107) onto shaft assembly (99) .

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Illustration 12	g01269976

Install planetary carrier (101) and spacer (100) onto shaft assembly (99). Raise the temperature of bearing cone (98). Install bearing cone (98) onto shaft assembly (99) .

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Illustration 13	g01269969
Intermediate Shaft

Install bearing (97) onto shaft assembly (80). Install gear (96), thrust washer (95), spacer (94), and gear (93) onto shaft assembly (80) .

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Illustration 14	g01269968

Install gear (92), spacer (91), and spacer (90) onto shaft assembly (80). Raise the temperature of bearing cone (89). Install bearing cone (89) onto shaft assembly (80) .

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Illustration 15	g01280589

Raise the temperature of bearing cone (88). Install bearing cone (88) onto shaft assembly (80) .

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Illustration 16	g01270211

Install thrust washer (83) onto shaft assembly (80). Install bearing (85) onto shaft assembly (80). Install gear (84), thrust washer (83), spacer (82), and spacer (81) onto shaft assembly (80). Raise the temperature of bearing cone (79). Install bearing cone (79) onto shaft assembly (80) .

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Illustration 17	g01270206

Install seal (78) onto piston (77). Install seals (76) onto shaft assembly (55) and piston (77). Install piston (77) onto shaft assembly (55) .

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Illustration 18	g02516957

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Illustration 19	g01269767

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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.

Use Tooling (K) in order to install spring (75). Install seal assembly (74) and spacer (73) onto shaft assembly (55). Use Tooling (J) in order to install retaining ring (71) .

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Illustration 20	g01269758

Install the friction discs and plates (70) onto shaft (55). Install clutch plate (69). Use Tooling (J) in order to install retaining ring (68). Install thrust washer (67) and bearings (66) .

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Illustration 21	g01269751
Reverse Shaft

Install gear (65) and thrust washer (64). Install spacer (63). Raise the temperature of bearing cone (62). Install bearing cone (62) .

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Illustration 22	g01269685

Install spacer (59), gear (58), spacer (57), and spacer (56) onto shaft assembly (55). Raise the temperature of bearing cone (54). Install bearing cone (54) onto shaft assembly (55) .

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Illustration 23	g02516016

Attach Tooling (F) and a suitable lifting device to shaft assemblies (52). The weight of shaft assemblies (52) is approximately 370 kg (820 lb). Install shaft assemblies (52) .

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Illustration 24	g02442529

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Illustration 25	g02442528

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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.

Install seals (46) and (48) onto piston (47) .

Install dowels (44) onto housing (45). Install springs (43). Install plates (42) and discs (41) .

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Illustration 26	g02442527

Install ring gear (40) and reaction plate (39). Install bolts (38) .

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Illustration 27	g02442526

Install O-ring seals (37) onto clutch assembly (35) .

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Illustration 28	g02442156

Note: Ensure that bolts marked (X) are in position prior to the installation of clutch assembly (35) .

Use two people in order to install clutch assembly (35). The weight of clutch assembly (35) is approximately 25 kg (55 lb). Install bolts (34) .

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Illustration 29	g02441421

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Illustration 30	g02440726

Note: Ensure that the gasket surfaces on the case assembly and the mating surface is clean and free of oil and grease.

Apply Tooling (M) to the gasket surface of case assembly (31) .

Position O-ring seals (33) .

Attach Tooling (A) and a suitable lifting device to case assembly (31). The weight of case assembly (31) is approximately 365 kg (800 lb). Install case assembly (31). Install bolts (30) and (32) .

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Illustration 31	g02461342

Lower the temperature of bearing cup (27a). Install bearing cup (27a) into bearing cage (27) .

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Illustration 32	g02519804

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Illustration 33	g02518716

Install bearing cage (27) and install bolts (26) .

Note: Rotate the shaft during the end play adjustment in order to seat the bearings properly.

Use Tooling (N) at pump drive Location (N) in order to rotate the shaft. This action will properly seat the bearings prior to checking the end play.

Attach Tooling (D) and a suitable lifting device to the shaft assembly. Install Tooling (D). Apply a slight lifting tension on the shaft assembly. Use Tooling (M) in order to check the end play of the shaft assembly. The end play should be .050 to 0.100 mm (0.002 to 0.004 inch). Add or remove shims (25) as required.

Repeat Step 35 through Step 37 for the other bearing cages.

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Illustration 34	g02475078

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Illustration 35	g02471757

Position retaining ring (153) onto shaft assembly (24) and install gear (152) .

Raise the temperature of bearing (151) and install the bearing onto shaft assembly (24) .

Install spacer (150) onto the shaft assembly.

Raise the temperature of bearing (154) and install the bearing onto shaft the other end of shaft assembly (24) .

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Illustration 36	g02440477

Attach Tooling (D) and a suitable lifting device to shaft assembly (24). The weight of shaft assembly (24) is approximately 75 kg (165 lb). Install shaft assembly (24) .

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Illustration 37	g02440536

Position gear (23) into place. Position retainer (22) and install bolt (21) .

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Illustration 38	g02461316

Lubricate the O-ring seals with the lubricant that is being sealed and install the O-ring seals onto tube assembly (28). Install the tube assembly and install bolt (29) .

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Illustration 39	g02687397

Lower the temperature of bearing cup (18) and install the bearing cup into the bearing cage.

Install O-ring seal (20) .

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Illustration 40	g02686661

Attach Tooling (A) and a suitable lifting device to Locations (X). The weight of cover assembly (12) is approximately 59 kg (130 lb). Position the cover assembly and install bolts (13) .

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Illustration 41	g02475239

Position bearing cage (16) and install bolts (15) .

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Illustration 42	g02518336
Typical Example

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Illustration 43	g02518716

Note: Rotate the shaft during the end play adjustment in order to seat the bearings properly.

Use Tooling (N) at pump drive Location (N) in order to rotate the shaft. This action will properly seat the bearings prior to checking the end play.

Attach Tooling (D) and a suitable lifting device to the shaft assembly. Apply a slight lifting tension to the shaft assembly. Use Tooling (L) in order to check the end play of the shaft assembly. The end play should be between 0.050 mm (0.0020 inch) and 0.100 mm (0.0039 inch). Add or remove shims as required.

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Illustration 44	g02687398

Reinstall the bearing cage using Tooling (C) to install lip seal and the O-ring seals.

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Illustration 45	g02518416

Install yoke (7), O-ring seal (4) (not shown), retainer (6), and bolt (5) .

Install tube assembly (14) .

If needed use Tooling (A) and a suitable lifting device in order to reposition the transmission. The weight of the transmission is approximately 1315 kg (2900 lb).

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Illustration 46	g02387596

Position yoke (11), O-ring seal (8) (not shown), retainer (10), and install bolt (9) .

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Illustration 47	g01270685

Lubricate lip seal (148) with the lubricant that is being sealed. Install lip seal (148) into seal ring housing (146) .

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Illustration 48	g01270632

Lubricate O-ring seals (147) with the lubricant that is being sealed. Install O-ring seals (147) into seal ring housing (146) .

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Illustration 49	g01279115

Install seal ring housing (146) and bolts (145) .

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Illustration 50	g02519020

Lubricate ring seals (53) with the lubricant that is being sealed. Install ring seals (53) onto seal carrier (61). Position seal carrier (61) and install bolts (60) .

Lubricate ring seals (53) with the lubricant that is being sealed. Install ring seals (53) onto seal carrier (87). Position seal carrier (87) and install bolts (86) .

Lubricate ring seals (53) with the lubricant that is being sealed. Install ring seals (53) onto seal carrier (114). Position seal carrier (114) and install bolts (115) .

Install the covers and O-ring seals.

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Illustration 51	g02440856

Position Yoke (51), O-ring seal (not shown), retainer (49), and install bolt (50) .

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Illustration 52	g02359576

Lubricate the input speed sensor O-ring seal with the lubricant that is being sealed prior to installation. Position harness assembly (3) and connect the harness assembly.