Rear Axle Trunnion Bolted Joints Caterpillar

Problem:

Compactors operating in industrial landfill applications may experience bolt loosening at the rear axle. This may be more evident on compactors equipped with rear axle attachment 2Z-9433 NoSPIN Differential Group.

Solution:

Install high strength bolts with pre-applied thread lock using the specified torque. Use the following procedure in order to install the new 160-8510 Bolts.

Rear Axle Rework Procedure

NOTE: One 154-9731 Thread Lock Compound (10 ml bottle) or one 155-0695 Thread Lock Compound (50 ml bottle) may be required.

1. Connect the steering frame lock.

2. Remove the rear drive shaft.

3. Remove the rear axle.

4. Place the axle housing assembly on wood blocks.

5. Remove the front trunnion support from the axle housing.

6. Inspect the front support bearing sleeve and seals. Replace if damaged.

7. Secure two 138-7573 Link Brackets to pinion housing (6). Attach hoist and suitable lifting slings to the link brackets.

8. Remove sixteen 6V-3532 Bolts (3) and sixteen 5P-8248 Washers (2) that hold 4E-1967 Pinion Housing (6) to carrier assembly (1).

9. Use two existing 6V-3532 Bolts to force pinion housing (6) from carrier assembly (1).

10. Use a hoist to remove the pinion housing from the carrier assembly.

11. Remove shim pack (5) and save for reuse.

12. Remove any dirt and oil from the bevel gear group carrier assembly internal threads. Inspect the threads for damage. Repair if needed.

13. Remove O-ring seal (4) from the opposite end of the pinion housing. Replace the seal with a new 8F-5900 O-ring Seal.

14. Install original shim pack (5) between the carrier assembly and the pinion housing.

15. Use a hoist and suitable lifting slings to carefully install the pinion housing onto the carrier assembly.

NOTE: The new 160-8510 Bolts are high strength, do not substitute. The new bolts have a pre-applied thread lock patch. If the thread lock patch was removed during shipping or handling, add a small amount of 154-9731 Thread Lock Compound (10 ml bottle) or 155-0695 Thread Lock Compound (50 ml bottle) to the bolt threads before assembly.

16. Install sixteen new 160-8510 Bolts with sixteen new 5P-8248 Washers into pinion housing (6). Do not lubricate the bolts threads or the internal threads of the carrier assembly. Tighten the 160-8510 Bolts to a torque of 230 ± 30 N·m (170 ± 22 lb ft). After all of the bolts have been tightened, check each bolt torque again in order to ensure no bolt has loosened. After checking each bolt for the correct torque, turn each bolt an additional 120 degrees ± 10 degrees.

17. Check the 36 6V-3532 Bolts (7) and 36 5P-8248 Washers (8) that hold carrier assembly (1) to the axle housing for loosening. Do this with a static inspection by tightening the bolts to a torque of 490 N·m (360 lb ft). If the bolts do not turn, the bolts are tight.

18. If the bolts turn, remove the bolts and inspect the internal threads of the axle housing. Repair if needed. Remove all dirt and oil from the housing threads and bolts. Apply a small amount of 154-9731 Thread Lock Compound (10 ml bottle) or 155-0695 Thread Lock Compound (50 ml bottle) to the bolt threads. Do not lubricate the bolt threads or the internal threads of the carrier assembly. Tighten the bolts to a torque of 230 ± 30 N·m (170 ± 22 lb ft). After all of the bolts have been tightened, check each bolt torque again in order to ensure no bolt has loosened. After checking each bolt for the correct torque, turn each bolt an additional 120 degrees ± 10 degrees.

NOTE: This bolted joint uses the same 6V-3532 Bolts and 5P-8248 Washers. If the bolts are damaged, replace the bolts with new 6V-3532 Bolts.

19. Remove twelve 6V-3532 Bolts (9) and twelve 8T-3282 Washers holding 130-0952 Thrust Plate (10) to the 118-9403 Trunnion.

20. Remove any dirt and oil from the trunnion internal threads. Inspect the threads for damage. Inspect the rear support bearing sleeve and seal. Repair if needed.

NOTE: The new 160-8510 Bolts are high strength, do not substitute. The new bolts have a pre-applied thread lock patch. If the thread lock patch was removed during shipping or handling, add a small amount of 154-9731 Thread Lock Compound (10 ml bottle) or 155-0695 Thread Lock Compound (50 ml bottle) to the bolt threads before assembly.

21. Install 130-0952 Thrust Plate (10) with twelve new 160-8510 Bolts and twelve 5P-8248 Washers. Do not lubricate the bolt threads or trunnion internal threads. Tighten the bolts to a torque of 230 ± 30 N·m (170 ± 22 lb ft). Turn bolts an additional 120 degrees ± 10 degrees.

22. Apply 5P-0960 Molybdenum Grease to thrust bearing (11). Install the thrust bearing into the rear trunnion support.

23. Apply 6V-5765 Sealant to the mating surfaces of the rear trunnion support and the cover. Install the cover, twelve bolts and the washers. Tighten the bolts to a torque of 530 ± 70 N·m (390 ± 50 lb ft).

24. Install the oscillating axle.

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