69D and 769D Off-Highway Truck and 771D Quarry Truck Power Train Caterpillar

Assembly Procedure

1. Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary.

2. Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.

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Illustration 1	g00490533

3. Cool roller bearing cup (1) to a temperature of -75 °C (-103 °F). Install roller bearing cup (1) into the differential carrier assembly.

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Illustration 2	g00490534

4. Heat roller bearing cones (3) and (4) to a maximum temperature of 135°C (275.0°F). Install roller bearing cones (3) and (4) onto pinion assembly (2) .

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Illustration 3	g01030176

5. Install Tooling (H) and a suitable lifting device to pinion assembly (2) . Install pinion assembly (2) into differential carrier assembly (5) .

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Illustration 4	g00490536

6. Cool roller bearing cup (6) to a temperature of -75 °C (-103 °F). Install roller bearing cup (6) onto bearing cage (8) .

   Note: Do not install lip seal (7) at this time.

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Illustration 5	g00490711

7. Install O-ring seal (9) on bearing cage (8) .

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Illustration 6	g00490709

8. Install bearing cage (8) and the shims. Install bolts (10) . Tighten bolts (10) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

9. Use the shims behind cage (8) to put a preload on the pinion bearings. Add the shims until the torque that is needed to turn pinion (2) is more than 4.0 N·m (35 lb in).

10. Turn pinion (2) for several revolutions. Change thickness of the shims so that a torque of 4.0 ± 0.6 N·m (35 ± 5 lb in) is needed to rotate the pinion.

11. Install lip seal (7) on bearing cage (8) at this time. The lip of lip seal (7) must be toward the pinion bearing. Refer to Illustration 4. Tighten bolts (10) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).

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Illustration 7	g00596102

12. Install O-ring seal (11) .

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Illustration 8	g00490713

13. Install yoke (13) and the collar on the pinion. Install the hard washer and locking bolt (12) .

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Illustration 9	g00490715

14. Position bolts (18) in differential housing assembly (16) .

15. Install thrust washer (15) in the differential housing assembly on dowels (17) . Install differential bevel gear (14) on thrust washer (15) .

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Illustration 10	g00576382

16. Position Tooling (A) in a suitable vise, as shown. Install retainer (19) to Tooling (A) .

    Note: Be sure that groove (21) is in alignment with dowel (22) .

17. Install roller bearing cone (20) to retainer (19) .

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Illustration 11	g00576481

18. Lower the temperature of roller bearing cups (23) and (24) to a temperature of -75 °C (-103 °F). Install roller bearing cups (23) and (24) to the differential pinion.

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Illustration 12	g00576483

19. Install the retainer and differential pinion (25) onto roller bearing cone (20) .

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Illustration 13	g00576484

20. Install roller bearing cone (26) into differential pinion (25) .

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Illustration 14	g00576486

21. Install nut lock (27) and nut (28) to the retainer.

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Illustration 15	g00576487

Note: Nut (29) is part of Tooling (A) .

22. Install nut (29) to the retainer.

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Illustration 16	g00576488

23. Position Tooling (B) on nut (28) . Rotate differential pinion (25) while you use Tooling (B) to tighten nut (28) . Rotate differential pinion (25) in order to ensure that the roller bearing assemblies are seated properly. Use Tooling (B) to tighten nut (28) to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

24. Bend nut lock (27) in order to prevent nut (28) from loosening.

25. Remove differential pinion (25) from Tooling (A) .

26. Repeat Steps 16 through 25 for the remaining differential pinions.

27. Remove nut (29) . Remove differential pinion (24) from the vise.

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Illustration 17	g00576491

28. Install differential pinions (25) to differential spider gear (30) .

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Illustration 18	g00490719

29. Position a suitable lifting sling around differential spider gear (30) . Attach the lifting sling to a suitable hoist. Install differential spider gear (30) and differential pinions (25) to differential housing assembly (16) . The weight of differential spider gear (30) and differential pinions (25) is approximately 36 kg (80 lb).

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Illustration 19	g00490745

30. Install differential bevel gear (32) and thrust washer (31) on the differential pinions.

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Illustration 20	g00490746

31. Position housing (33) on differential ring gear (35) . Apply 4C-5593 Anti-Seize Compound on the threads of bolts (34) . Install bolts (34) and the washers. Tighten bolts (34) to a torque of 440 ± 40 N·m (325 ± 30 lb ft). The weight of housing (33) is approximately 41 kg (90 lb).

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Illustration 21	g00490754

Note: Ensure that the alignment marks on housing (33) and differential housing assembly (16) are aligned.

32. Position housing (33) on differential housing assembly (16) . Ensure that the notch in the thrust washer aligns with the dowels in housing (33) . The weight of housing (33) and the ring gear is approximately 82 kg (180 lb).

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Illustration 22	g00490755

33. Install locknuts (34) and the washers onto bolts (18) . Tighten locknuts (34) to a torque of 395 ± 20 N·m (291 ± 15 lb ft).

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Illustration 23	g00576856

34. Position the differential on two suitable "V" blocks, as shown. Use Tooling (C) in order to turn the differential bevel gear clockwise for two revolutions. Turn differential bevel gear counterclockwise for two revolutions. The torque that is required to turn the pinion assemblies must not exceed 35 N·m (26 lb ft).

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Illustration 24	g00576935

35. Raise the temperature of roller bearing cones (35) to a maximum temperature of 135°C (275.0°F). Install roller bearing cones (35) to each side of the differential.

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Illustration 25	g00490758

36. Install roller bearing cup (36) and adjustment ring (37) on each side of the differential.

37. Install a bar (X) through the differential, as shown. Attach two lifting slings to bar (X) . Attach the lifting slings to a hoist. Install the differential in differential carrier (38) . The weight of the differential carrier (38) is approximately 197 kg (435 lb).

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Illustration 26	g00490761

38. Align dowel (40) in bearing caps (39) with the hole in bearing cage (36) . Install bearing caps (39) to each side of the differential. Install the bolts that hold bearing caps (39) in place.

    Note: Do not tighten the bolts that hold bearing caps (39) at this time.

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Illustration 27	g00490763

39. Put the differential and bevel gear in position on Tooling (E) . Ensure that the teeth on the differential ring gear are facing upward.

40. Use Tooling (D) in order to check movement of the differential bevel gear, as shown. Use Tool (F) in order to turn the adjustment ring that is located on the bottom of the differential and bevel gear until there is 0.36 ± 0.13 mm (0.014 ± 0.005 inch) backlash between the differential bevel gear and the pinion.

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Illustration 28	g00490770

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Illustration 29	g00577412

41. Use Tooling (G) in order to check movement of adjustment ring (6) , as shown. Use Tooling (F) in order to turn the top adjustment ring (37) until dimension (Y) has an increase of 0.508 mm (0.020 inch) to 0.635 mm (0.025 inch).

42. Rotate the differential bevel gear in each direction for a total of 30 seconds. Use Tooling (F) in order to turn the top adjustment ring (37) until dimension (Y) decreases to 0 mm (0 inch).

43. Use Tooling (F) in order to turn the top adjustment ring (37) until dimension (Y) increases to 0.381 ± 0.051 mm (0.015 ± 0.002 inch).

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Illustration 30	g00490772

44. Tighten bolts (42) to a torque of 1100 ± 150 N·m (811.3 ± 110.6 lb ft).

45. Install the lock, locking bolt (41) and the washer to the bearing cap.

End By: Install the differential and bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Install".