768C TRACTOR & 769C TRUCK POWER TRAIN DISASSEMBLY & ASSEMBLY Caterpillar

Torque Converter

Usage:

Remove Torque Converter

start by:

a) remove drive shaft (front)

1. Lift the body of the truck and put FT1437 Body Support in position. See INSTALL AND REMOVE BODY SUPPORT on Page 7.

2. Drain the oil from the transmission, brake and hoist hydraulic tank. The capacity of the tank is 44 U.S. gal. (166.5 liter).

3. Put identification on all the lines that are removed. Remove converter lock-up signal line (1), scavenge return line (3), transmission scavenge line (4) and pump drive drain line (2).

4. Remove wire (7) from the sending unit. Remove torque converter supply line (6). Remove line (5) from the inlet relief valve and remove line (8) from the outlet relief valve.

5. Disconnect hoses (9) and (10) from the top of the torque converter.

6. Remove bolt (11) that fastens clip (12) to the torque converter. Remove bolt (13) and retainer.

7. Install two 5/8"-11 NC forged eyebolts (14) in the top of the torque converter and fasten a hoist as shown. Remove the bolts that fasten the torque converter to the flywheel housing. Move the torque converter away from the flywheel housing and lower the torque converter to the floor. The weight of the torque converter is 740 lb. (338 kg).

Install Torque Converter

1. Inspect the condition of all O-ring seals and make replacements if necessary.

2. Install two 5/8"-11 NC forged eyebolts (1) in the top of the torque converter housing and fasten a hoist as shown. Install O-ring seals (2) and (3). Lift the torque converter into position and install the bolts and lockwashers that fasten the torque converter to the flywheel housing.

3. Install the retainer with bolt (6). Install clip (5) on the torque converter housing with bolt (4) and lockwasher.

4. Connect hoses (7) and (8) to the fitting on the top of the torque converter housing.

5. Install O-ring seals on lines (9), (10) and (12). Install torque converter supply line (10). Install line (9) on the inlet relief valve and install line (12) on the outlet relief valve. Install wire (11) on the sending unit.

6. Install O-ring seals on lines (15) and (16). Install torque converter lock-up line (13), pump drive drain line (14), scavenge return line (15) and transmission scavenge line (16).

7. Fill the transmission, brake and hoist hydraulic tank with oil. See LUBRICATION AND MAINTENANCE GUIDE.

end by:

a) install drive shaft (front)

Disassemble Torque Converter

start by:

a) remove torque converter

1. Remove O-ring seal (1) from torque converter cover (2). Remove tube (3) from the cover.

2. Remove bolt (4), plate, shims, O-ring seal and flange (5). Remove bolts (6) and lockwashers that fasten the cover to the torque converter.

3. Use three 1/2"-13 NC forcing screws (7) to make a separation of the cover and converter. Remove the forcing screws.

4. Install tooling (A) and fasten hoist as shown. Remove the cover from the torque converter. The weight of the cover is 340 lb. (153 kg).

5. Remove bolts (8) and remove pilot (9) from housing (10).

6. Remove two bolts (11), plate (12) and shims from the shaft.

7. Turn the torque converter assembly over. The weight of the converter assembly is 400 lb. (180 kg). Remove two O-ring seals (15). Remove bolts (13), lockwashers, retainer (14) and gasket.

8. Remove lip type seal (16) from retainer (14).

9. Remove shaft assembly (17) from the converter.

10. Put a support under carrier (19). Use a press to push the shaft out of bearing (18) and the carrier.

11. Remove retainer ring (21) that holds carrier (20) on the carrier assembly with tool (D). Remove the carrier from the converter assembly.

12. Remove retainer ring (22) that holds sleeve (23) and bearing (24) in carrier (20).

13. Use tooling (C) to remove sleeve (23) and bearing (24) from the carrier.

14. Use tool (D) to remove retainer ring (25) from carrier assembly (26). Remove bolts (27) and washers that fasten plate (28) and the impeller to housing (10).

15. Install two 3/8'-16 NC forged eyebolts and fasten a hoist as shown. Use two 3/8"-16 NC forcing screws (29) to make a separation of the impeller and the housing. Remove the plate and impeller from the housing. The weight of the impeller assembly is 65 lb. (29 kg).

16. Use tooling (E) to remove bearing race (30) from the hub.

17. Use tooling (F) to remove carrier (31) from the hub.

18. Remove bolts (34) that hold hub (33), gear (32), plate (28) and impeller together. Remove the gear and plate from the hub and impeller.

19. Remove O-ring seal (36) and impeller (35) from hub (33).

20. Remove race and retainer assembly (37) and bearing from the stator assembly.

21. Use two persons to remove stator and carrier assembly (38) from the turbine and housing. The weight of the stator and carrier assembly is 62 lb. (28 kg).

22. Remove plate (39) from the stator assembly.

23. Remove carrier assembly (26) from the stator assembly (38). Remove springs (40) and rollers (41) from the stator assembly.

24. Remove ring (42) from carrier (26). Remove bearing (43) from the carrier only if a replacement is needed. Removal can cause damage to the bearing.

25. Remove retainer ring (44) and plate (45) from the stator.

26. Remove retainer ring (46) from the stator. Heat the stator to a maximum temperature of 275°F (135°C) for approximately fifteen minutes. Push cam (47) out of the stator.

27. Remove bearing (48), race and retainer from turbine (49).

28. Turn the housing and turbine over and set the housing on wood blocks. Use a hammer and soft punch (brass, aluminum) to push hub (50) and turbine assembly out of bearing race (51). Remove the race and bearing.

29. Remove bolts (52) and hub (53) from turbine (49).

30. Remove ring (55) from the hub. Remove bearing race (54) from the hub only if a replacement is needed. Removal can cause damage to the bearing race.

31. Remove retainer ring (56) from housing (10). Remove plate (57). Remove the two clutch plates and discs from the housing.

32. Use two 3/8"-16 NC forged eyebolts to remove piston (58) from the housing.

33. Remove seals (59) from piston (58) and housing (10).

34. Remove bearing race (60) from housing (10) only if a replacement is needed. Removal can cause damage to the bearing race.

Assemble Torque Converter

1. Make sure all parts of the torque converter are clean and free of dirt and foreign material before it is assembled.

2. Check the clearance between the turbine and the stator. The difference between dimension (N), the turbine inner diameter and dimension (M), the stator outer diameter must be .028 to .036 in. (0.71 to 0.91 mm) with new parts. The maximum permissible clearance with worn parts is .054 in. (1.37 mm).

3. Check the clearance between the impeller and the stator. The difference between dimension (P), the inner diameter of the impeller, and dimension (Q), the outer diamter of the stator, must be .028 to .036 in. (0.71 to 0.91 mm) with new parts. The maximum permissible clearance with worn parts is .054 in. (1.37 mm).

4. Check the clearance between the stator and the turbine. The difference between dimension (R), the inner diameter of the turbine, and dimension (S), the outer diameter of the stator, must be .022 to .028 in. (0.56 to 0.71 mm) with new parts. The maximum permissible clearance with worn parts is .042 in. (1.07 mm).

TYPICAL EXAMPLE

5. If bearing race (1) has been removed, lower the temperature of the bearing race and install in housing (2) until the race makes contact with the shoulder in bottom of the bearing race bore.

6. Install seals (4) on piston (3) and in housing (2).

7. Install piston (3) in the housing.

8. Put hub (5) in position in the housing. Install two discs (7) and two plates (6). Start with a disc.

9. Install plate (8) and retainer ring (9) that holds the plate in the housing. Remove hub (5) from the housing.

10. If bearing race (11) was removed, heat the race to 275°F (135°C) and install on the hub until the race makes contact with the shoulder on the hub. Install ring seal (10) on the hub.

11. Install hub (5) on turbine (13) with bolts (12). Tighten the bolts to a torque of 81 ± 4 ft.lb. (111 ± 5 N·m).

12. Install bearing (14) and turbine (13) in the housing. The bearing must be held in position in the housing when the turbine is installed.

13. Install race and retainer assembly (16) and bearing (15) on the hub. Be sure the notch in the race is in alignment with pin (17) on the hub.

14. Use a press and tooling (A) to inltall the bearing in carrier (18). The installed bearing must be .06 ± .02 in. (1.52 ± 0.51 mm) below the surface of the carrier.

15. Install ring seal (19) on the carrier.

NOTE: There is identification on the cam that shows "IMPELLER SIDE" of the cam.

16. Install retainer ring (20) in stator (21). Heat the stator to a maximum temperature of 275°F (135°C). Install cam (22) in the stator as shown with the "IMPELLER SIDE" down. Install the cam until it makes contact with ring (20).

17. Install plate (24) and ring (23) in the stator.

Show/hide table

NOTICE

The springs must be installed with the maximum number of loops toward the outside (cam side).

18. Turn the stator over and install carrier (18) as shown. Install springs (26) and rollers (25) in the cam with the springs in the deeper part of each cam groove.

19. Install plate (27) on the stator and carrier assembly.

Show/hide table

NOTICE

The stator must be held in position on the carrier when the assembly is installed.

20. Install the stator and carrier assembly in the turbine.

21. Install bearing (29) and retainer and race assembly (28) on the stator.

22. Install two 1/2"-13 NC guide pins in hub (30). Install impeller (31) on the hub. Install O-ring seal (32) on the hub.

23. Install plate (34) and gear (33) on the hub. Remove the guide pins and install the bolts that fasten the gear to the hub. Tighten the bolts to a torque of 81 ± 4 lb.ft. (111 ± 5 N·m).

24. Heat carrier (36) and race (35) to 275°F (135°C). Install the carrier and race on the hub. When the carrier becomes cooler, install the ring seal on the carrier.

25. Install two 3/8"-16 NC guide pins in housing (2). Install two 3/8"-16 NC forged eyebolts in the impeller assembly and install the impeller assembly on the housing. The weight of the impeller assembly is 65 lb. (29 kg). Install the bolts that fasten the plate and impeller to the housing.

26. Install retainer ring (37) with tool (B).

27. Lower the temperature of bearing (41) and sleeve (39). Install the bearing and sleeve in carrier (40). Install retainer ring (38) in the carrier.

28. Install carrier assembly (40) on carrier (18).

29. Use tool (B) to install retainer ring (42) that holds carrier (40) on carrier (18).

30. Use a press to install carrier (44) on shaft (43) until the carrier makes contact with the shoulder on the shaft.

31. Install two seal rings (45) on the carrier.

32. Install bearing (46) on the shaft.

33. Install the lip type seal in retainer (47) with tooling (A). Install the seal with the seal lip toward the inside of the retainer. Put a thin layer of SAE 30 oil on the seal lip.

34. Put shaft assembly (43) in position in the converter. Install a new gasket (48) between the retainer and carrier. Put the retainer in position on the carrier and install the bolts and lockwasher that hold the retainer on the carrier.

35. Install two O-ring seals (49) on the carrier.

36. Turn the converter assembly over. Install bearing race (50) on hub (5) with a hammer and soft punch (brass or aluminum).

37. Measure the thickness of plate (51).

38. Measure the distance from plate (51) to the end of shaft (43).

39. The thickness of the gap between the plate and the end of the shaft is the difference between the dimension found in Steps 37 and 38.

40. Install shims between plate (51) and shaft (43) that have a total thickness of .001 to .003 in. (0.03 to 0.08 mm) less than the gap found in Step 39. Install the bolts that fasten the plate to the shaft. Tighten the bolts to a torque of 55 ± 5 lb.ft. (75 ± 7 N·m).

41. Install pilot (52) on the housing. Install the bolts that fasten the pilot to the housing. Tighten the bolts to a torque of 36 ± 2 lb.ft. (46 ± 3 N·m).

42. Turn the converter over. Install two 1/2"-13 NC guide pins in the carrier. Install tooling (C) on cover (53) and fasten a hoist. Be sure the gear on torque converter is in alignment with the gear on the transmission and torque converter scavenge pump. Put the cover in position on the torque converter. Install the bolts and lockwashers that fasten the cover to the converter. The weight of the cover is 340 lb. (153 kg).

43. Put flange (54) in position on the shaft. Measure the distance between the end of shaft (43) and the shoulder on the flange that makes contact with the retainer plate.

44. Install O-ring seal (56) in the flange. Install shims (55) that have a total thickness of .005 to .010 in. (0.13 to 0.25) less the dimension found in Step 43. Install retainer plate (57) with a bolt. Tighten The bolt to a torque of 200 ± 10 lb.ft. (270 ± 14 N·m).