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	g03328001

3. If necessary, install dowel (156). Install the end of the dowel 1.00 ± 0.13 mm (0.039 ± 0.005 inch) above the bearing surface on the housing.

4. If carrier (155) was removed from the housing, heat the new carrier (155) to a temperature of 135°C (275.0°F). Install the carrier on the housing assembly. Align the small groove in the carrier with the pin hole in the housing assembly. Install pin (154).
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   Illustration 2	g00491967

5. Position housing assembly (124) on Tooling (A), as shown.

6. Put shaft assembly (152) in position in housing assembly. Install retaining ring (151) with Tooling (C) (not shown).

7. Install seal ring (153) in housing assembly (124).

8. If the dowels were removed from housing (124), install the dowels to a depth of 7.50 ± 0.50 mm (0.295 ± 0.020 inch).
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   Illustration 3	g03328037

9. Install seal extension ring (150) into the groove in clutch piston (149).

10. Attach Tooling (E) to clutch piston (149). Install clutch piston (149) in housing assembly (124).
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    Illustration 4	g00491964

11. If the dowel was removed from gear assembly (140), install the dowel. Position the dowel 2.04 ± 0.13 mm (0.080 ± 0.005 inch) above the surface of gear (140).

12. Install seal ring (147) in gear assembly (140).
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    Illustration 5	g03328065

13. Install seal extension ring (146) in balance piston (145).

14. Position balance piston (145) on gear assembly (140). Align the notch in ball bearing (144) with the pin in gear assembly (140). Install ball bearing (144).
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    Illustration 6	g03328066

15. Use Tooling (C) (not shown) to install retaining ring (143) that holds ball bearing (144) to the gear.
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    Illustration 7	g03328067

16. Install twelve retainer springs (148) in clutch piston (149). Install gear (140) in housing assembly (124).

17. Install six bolts (not shown) under housing assembly (124) in order to secure gear assembly (140).
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    Illustration 8	g03327774

18. Install three friction discs (141) and two plates in housing assembly (124). Install a friction disc on the bottom of the stack. Install the friction discs and plates in alternating order. Start with a friction disc (141) and end with a friction disc (141).

19. Install seal ring (142) on gear (141).
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    Illustration 9	g03328078

20. Install bearings (133) and (137) in planetary gears (134) and (138). Install planetary gears and thrust discs (132), (135), (136), and (139) in position in carrier assembly (127).
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    NOTICE
    The spring pins must be replaced with new parts during the assembly of the carrier assembly. Failure to use new spring pins could result in damage to the carrier assembly.

21. Install planetary shaft (130) in position in the carrier assembly. Align the hole in the planetary shaft with the hole in the carrier assembly. Install new spring pin (131).

22. Repeat Steps 20 and 21 for the remaining five gears.
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    Illustration 10	g00491959

23. Install ring seal (129) into the groove in carrier assembly (127).
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    Illustration 11	g03328082

24. Use Tooling (D) in order to install bearing (128) in carrier assembly (127). The inside diameter of bearing (128) must be 112.547 ± 0.078 mm (4.4310 ± 0.0031 inch) after assembly.
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    Illustration 12	g03327115

25. Attach Tooling (L) to carrier assembly (127). Put carrier assembly (127) on housing assembly (124). Rotate carrier assembly (127) in order to align carrier assembly (127) with housing assembly (124). Put carrier assembly (127) on the dowels. Install bolts (126) that hold carrier assembly (127). The weight of carrier assembly (127) is approximately 30 kg (66 lb).
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    Illustration 13	g00493875
    The photo shows the correct method to make new seal rings ready for installation.

    Note: Use the following procedure in order to make the seal rings ready for installation: Pull one end of the seal ring past the other end of the seal ring. Refer to Illustration 13. Use care to keep the seal ring circular. This makes an even bend all the way around the seal ring. When the seal ring is in the groove, the ends must contact each other. The seal ring must not contact the edge of the bore.

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    Illustration 14	g00493876
    The photo shows an incorrect method to make new seal rings ready for installation.

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    Illustration 15	g00491956

26. Invert the housing. Place the housing assembly on a flat surface.

27. Install two seal rings (125) in housing assembly (124).
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    Illustration 16	g03327207

28. Position the housing assembly onto Tooling (A) (not shown). Attach Tooling (B) and a suitable lifting device to center manifold (121). Install center manifold (121) on the housing assembly. The weight of center manifold (121) is approximately 50 kg (110 lb).

29. Position baffle assembly (120) on center manifold (121). Install the two bolts.
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    Illustration 17	g03328175

30. Align the notch in ball bearing (123) with dowel (156). Install ball bearing (123) in the center manifold. Use Tooling (C) to install retaining ring (122).
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    Illustration 18	g03328181

31. If dowel (157) was removed, install dowel (157) in manifold assembly (118). Position dowel (157) 2.043 ± 0.13 mm (0.0804 ± 0.005 inch) above the bearing surface of manifold assembly (118).

32. Install two seal rings (119) into the grooves in manifold assembly (118).
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    Illustration 19	g03328184

33. Install Tooling (S) in center manifold (121). Align the ports in manifold assembly (118) with the ports in center manifold (121). Install manifold assembly (118). Install the six bolts that hold manifold assembly (118) to center manifold (121).
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    Illustration 20	g03328245

34. Install seal ring (117) into the groove in housing assembly (110).

35. Install seal extension ring (116) in clutch piston (115).

36. Install clutch piston (115) in housing assembly (110).

37. If the dowels were removed from housing assembly (110), install the dowels in housing assembly (110). Install the dowels to a depth of 7.5 ± 0.5 mm (0.30 ± 0.02 inch).
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    Illustration 21	g03327382

38. Attach Tooling (N) and a suitable lifting device to housing assembly (110). Install the clutch piston and housing assembly (110) in center manifold (121). The weight of the clutch piston and housing assembly (110) is approximately 26 kg (57 lb).

39. Install 16 retainer springs (114) in the clutch piston.
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    Illustration 22	g03328260

40. Use Tooling (D) to install ball bearing (112) in balance piston (109). Install retaining ring (111) with Tool (H) (not shown).

41. Install ring (113) into the groove in balance piston (109).
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    Illustration 23	g03328262

42. Install Tooling (S) in balance piston (109). Align the notch in the ball bearing in balance piston (109) with the dowel in the carrier. Install balance piston (109).
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    Illustration 24	g03328298

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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.

43. Remove Tooling (S). Install the bolts. Tighten the bolts evenly in order to prevent binding of balance piston (109) in the housing assembly.

44. Install metal seal ring (107) in manifold assembly (118).
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    Illustration 25	g03328336

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    Illustration 26	g03327386

45. If dowel (158) was removed from balance piston (109), install dowel (158) in balance piston (107). Position dowel (158) 2.043 ± 0.13 mm (0.0804 ± 0.005 inch) above the bearing surface of the balance piston.

46. Install metal seal ring (106) in balance piston (109).

47. Install sun gear assembly (105) and metal seal ring (106).

48. Install two clutch plates and two friction discs (108) on balance piston (109). Install the clutch plates and the friction discs in alternating order. Start with a clutch plate and end with a friction disc.
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    Illustration 27	g00491930

49. Position bearing (101) in planetary gear (102). Install planetary gear (102), thrust disc (103), and thrust disc (104) in carrier assembly (98).

50. Install planetary shaft (99) in carrier assembly (98).
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    NOTICE
    The spring pins must be replaced with new parts during the assembly of the carrier assembly. Failure to use new spring pins could result in damage to the carrier assembly.

51. Align the hole in planetary shaft (99) with the hole in carrier assembly (98). Install spring pin (100).

52. Repeat Steps 49 through 51 for the remaining three gears.
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    Illustration 28	g03328341

53. If dowels (159) were removed from carrier assembly (98), install dowels (159). Position dowels (159) to a depth of 5.0 ± 0.5 mm (0.20 ± 0.02 inch).

54. Attach Tooling (M) and a suitable lifting device to carrier assembly (98). Position carrier assembly (98) on the dowels of housing assembly (110). Install the 15 bolts that hold the carrier assembly in place.
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    Illustration 29	g03328354

55. If pins (95) and (160) were removed from plate (94), install three pins. Position two pins (95) to a depth of 10.0 ± 0.5 mm (0.39 ± 0.02 inch). Install pin (160) in plate (94).

56. Align the pins in plate (94) with the holes in the center manifold. Install plate (94).
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    Illustration 30	g03328356

57. Position ring gear (96) on the carrier assembly. Install dowels (91) into the holes in plate (94).

58. Install two friction discs (90) and clutch plate (93) on ring gear (96). Install a friction disc (90) on each side of clutch plate (93).

59. Install ten springs (92) in plate (94).
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    Illustration 31	g03328357

60. Put seal extension ring (161) and ring seal (162) into the grooves in clutch piston (89).
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    Illustration 32	g00491916

61. Install clutch piston (89) in clutch housing (88).
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    Illustration 33	g03326400

62. Attach Tooling (E) in position in order to hold the clutch piston in clutch housing (88).

63. Attach Tooling (B) and a suitable lifting device to clutch housing (88). Position clutch housing (88) on the dowels. Ensure that the springs in the plate assembly align with the holes in the clutch piston. The weight of clutch housing (88) and the clutch piston as a unit is approximately 24 kg (53 lb).
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    Illustration 34	g03328362

64. If dowels (86) were removed from clutch housing assembly (87), install four dowels (86). Position dowels (86) to a depth of 11.0 ± 0.5 mm (0.43 ± 0.02 inch) in housing assembly (80).

65. Attach Tooling (F) and a suitable lifting device to clutch housing assembly (87). Align dowels (86) in the bottom of clutch housing assembly (87) with the holes in clutch housing (88). Install clutch housing assembly (87).
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    Illustration 35	g03328473

66. Install seal extension ring (163) and ring seal (164) into the grooves in clutch piston (85).
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    Illustration 36	g03328477

67. Install clutch piston (85) in clutch housing assembly (87).
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    Illustration 37	g03328481

68. Use a screwdriver to install retaining ring (83) in ring gear (84). Install ring gear (84) with the ring on the bottom.
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    Illustration 38	g03328483

69. Install plate (82) onto dowels (165). Install the six bolts that hold plate (82).
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    Illustration 39	g03328489

70. Install metal seal ring (80) in plate (79).
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    Illustration 40	g03328490

71. Position plate (79) with the counterbore on top. If plate (79) is installed incorrectly, ball bearing (78) will not seat correctly.

72. Align the notch in ball bearing (78) with dowel (158). Install ball bearing (78).
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    Illustration 41	g00491874

73. Install sun gear (76). Use Tool (C) (not shown) to install retaining ring (75).
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    Illustration 42	g03328511

74. Install bearings (71) in planetary gear (74). Position planetary gear (74) and thrust discs (73) and (72) in carrier assembly (57). Install (69) in carrier assembly (57).
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    NOTICE
    The spring pins must be replaced with new parts during the assembly of the carrier assembly. Failure to use new spring pins could result in damage to the carrier assembly.

75. Align the hole in planetary shaft (69) with the hole in carrier assembly (57). Install spring pin (70).
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    Illustration 43	g03328518

76. Use a suitable press and Tooling (P) in order to install bearing (68) in carrier assembly (57). Position bearing (68) 9.5 ± 0.5 mm (0.37 ± 0.02 inch) below the surface of the end of the carrier assembly. The inside diameter of bearing (68) must be 41.262 ± 0.039 mm (1.6245 ± 0.0015 inch) after assembly.
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    Illustration 44	g03328521

77. Attach Tooling (M) and a suitable lifting device to carrier assembly (57). Align the planetary gears in carrier assembly (57) with ring gear (84). Install carrier assembly (57) and the bolts.
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    Illustration 45	g00491858

78. Position sun gear (65) in coupling hub (66). Use Tooling (C) in order to install retaining ring (67).
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    Illustration 46	g03328531

79. Put five dowels (45) in the housing assembly.

80. Install four friction discs (62) and three clutch plates (64) in alternating order. Start with a friction disc and end with a friction disc.

81. Install ten springs (63) on the clutch piston.
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    Illustration 47	g03328538

82. If dowels (61) were removed from clutch housing assembly (59), install dowels (61). Position dowels (61) to a depth of 11.0 ± 0.5 mm (0.43 ± 0.02 inch).

83. Attach Tooling (K) and a suitable lifting device to clutch housing assembly (59).

84. Align the ports in clutch housing assembly (59) with the ports in clutch housing assembly (87). Put clutch housing assembly (59) on dowels (45). Align springs (63) with the holes in clutch housing assembly (59).
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    Illustration 48	g03328559

85. Install seal extension ring (165) and ring seal (166) into the grooves of clutch piston (60).
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    Illustration 49	g03328568

86. Install clutch piston (60) in clutch housing assembly (59).
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    Illustration 50	g00491853

87. Install metal seal ring (58) on carrier assembly (57).
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    Illustration 51	g00491848

88. Install bearings (53) in planetary gear (56). Put the planetary gear and thrust discs (55) and (54) in planetary carrier (50).

89. Install shaft assembly (51) in the planetary carrier.
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    NOTICE
    The spring pins must be replaced with new parts during the assembly of the carrier assembly. Failure to use new spring pins could result in damage to the carrier assembly.

90. Align the hole in shaft assembly (51) with the hole in planetary carrier (50). Install spring pin (52).

91. Repeat Steps 88 through 90 for the remaining three gears.
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    Illustration 52	g03328587

92. Attach Tooling (L) and a suitable lifting device to planetary carrier (50). Align planetary carrier (50) with the shaft assembly. Install planetary carrier (50). The weight of planetary carrier (50) is approximately 24 kg (53 lb).

93. Position speed adapter (47) on planetary carrier (50). Install the four bolts that hold speed adapter (47) to the planetary shaft.

94. Support the weight of planetary carrier (50) with the hoist. Install retaining ring (48) with Tooling (G).
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    Illustration 53	g03328625

95. Position ring gear (42) in position on planetary carrier (50).

96. Install five friction discs (43) and four plates (46) on ring gear (42) in alternating order. Start with a friction disc (43) and end with a friction disc (43).

97. Install ten springs (44) into the clutch piston.
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    Illustration 54	g03328627

98. Use a suitable press and Tooling (D) in order to install roller bearing assembly (40) and bearing cup (41) in end plate (29) as an assembly.
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    Illustration 55	g03328631

99. Use a suitable hydraulic press in order to install bearing cup (41). Install spacer (39). Install bearing cone (38).
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    Illustration 56	g03328636

100. Use Tooling (D) in order to install lip seal (37) in bearing retainer (36).
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     Illustration 57	g03328641

101. Install O-ring seal (167) on bearing retainer (36). Install bearing retainer (36) on end plate (29).
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     Illustration 58	g03328647

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     Illustration 59	g03328721

102. Position end plate (126), as shown. Attach Tooling (B) and a suitable lifting device to end plate (29).

103. Position end plate (29) over yoke assembly (33). The weight of end plate (29) is approximately 50 kg (111 lb).

104. Position retainer plate (32) on the yoke assembly. Install four evenly spaced twelve point head bolts (31) around retainer plate (32). Do not tighten bolts (31) at this time.

105. Use a feeler gauge in order to measure the gap between yoke assembly (33) and retainer plate (32). Measure the gap in four places. Find the average of the measurements.

106. Remove four twelve point head bolts (31) and retainer plate (32). Install the shims with a thickness of 0.03 to 0.08 mm (0.0012 to 0.0031 inch) less than the average gap.

107. Position retainer plate (32) on the shims. Install twelve twelve point head bolts that hold retainer plate (32) to yoke assembly (33).
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     Illustration 60	g03328728

108. Attach Tooling (F) and a suitable lifting device to housing (29). Align the splines in yoke assembly (33) with the splines on the planetary carrier. Put the end plate on dowels (45). Ensure that springs (44) engage the holes in end plate (29). The weight of housing (29) is approximately 70 kg (154 lb).
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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.

109. Install the 20 bolts that hold end plate (29) to the transmission planetary.
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     Illustration 61	g03328738

110. Attach Tooling (F) (not shown) and a suitable lifting device to the transmission planetary. Position the transmission planetary upside-down on Tooling (A). The weight of the transmission planetary is approximately 454 kg (1000 lb).

111. If pins (27) and (168) were removed from plate assembly (28), install two pins. Install two pins to a depth of 10.0 ± 0.5 mm (0.39 ± 0.02 inch). Install pin (138) in the plate assembly.

112. Position plate assembly (28) on the manifold.
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     Illustration 62	g03328759

113. Install five reaction dowels (22) in housing assembly (28).

114. Install ring gear (26) on the carrier assembly.

115. Install three friction discs (24) and two clutch plates (25) over the ring gear in alternating order. Start with a friction disc (24) and end with a friction disc (24).

116. Install ten springs (23) in plate assembly (28).
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     Illustration 63	g03328761

117. Install seal extension ring (169) and ring seal (170) in the grooves of clutch piston (21).
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     Illustration 64	g00491411

118. Install clutch piston (21) into clutch housing (20).
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     Illustration 65	g03328766

119. Position Tooling (E) in order to hold the clutch piston in clutch housing (20).

120. Attach Tooling (K) and a suitable lifting device to clutch housing (20). Position clutch housing (20) on dowels (22). Ensure that springs (23) engage the holes in clutch housing (20). The weight of clutch housing (20) and the clutch piston as a unit is approximately 28 kg (62 lb).
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     Illustration 66	g00491407

121. Install sun gear (14) in clutch hub assembly (11).
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     Illustration 67	g03328772

122. Install retainer ring (13) that holds the sun gear to clutch hub assembly (11).

123. If dowel (171) was removed from clutch hub assembly (11), install dowel (171). Install the end of dowel (171) 2.403 ± 0.13 mm (0.0946 ± 0.005 inch) above the bearing surface of clutch hub assembly (11).
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     Illustration 68	g00491405

124. Use Tooling (D) in order to install ball bearing (12) in bearing cage (9).
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     Illustration 69	g03328777

125. Align the notch in ball bearing (12) with the dowel in clutch hub assembly (11). Install ball bearing (12) and the bearing cage on clutch hub assembly (11) as an assembly.

126. Use Tool (C) in order to install retainer ring (10) in clutch hub assembly (11).
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     Illustration 70	g03328778

127. Install manifold (8) onto bearing cage (9). Install four bolts (172) and the washers.
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     Illustration 71	g03328798

128. Attach Tooling (B) to bearing cage (9). Align clutch hub assembly (11) with carrier assembly (127). Install clutch hub assembly (11), bearing cage (9), and the manifold as an assembly.
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     Illustration 72	g03328822

129. Install five dowels (16) and ten springs (17) in the holes in clutch housing (20).

130. Install two friction discs (19) and clutch plate (18) on clutch housing (20) in alternating order. Start with a friction disc (19) and end with a friction disc (19).
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     Illustration 73	g03328832

131. Install seal extension ring (173) and ring seal (174) into the grooves of clutch piston (15).
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     Illustration 74	g03328837

132. Install clutch piston (15) on dowels (16) and springs (17). Ensure that the springs engage the holes in clutch piston (15).
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     Illustration 75	g03328838

133. Install Tooling (T) in the manifold. Attach Tooling (K) to housing assembly (7). Position housing assembly (7) on the transmission planetary. The weight of housing assembly (7) is approximately 32 kg (70 lb).
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     Illustration 76	g03329293

134. Install eight bolts (175) that hold clutch housing assembly (7) to the manifold.

135. Install two bolts (176) and eight bolts (6) that hold housing assembly (7) to the transmission planetary.
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     Illustration 77	g03329354

136. Remove transmission planetary (1) from Tooling (A). The weight of transmission planetary is 610 kg (1350 lb).

137. Position case (4) on Tooling (A). The weight of case (4) is approximately 205 kg (450 lb).

138. Install O-ring seal (177) on transmission planetary (1).

139. Attach Tooling (B) and a suitable lifting device to transmission planetary (1). Position transmission planetary (1) in case (4). Install the bolts that fasten transmission planetary (1) to case (4). The weight of transmission planetary (1) is approximately 610 kg (1350 lb).
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     Illustration 78	g03329370

140. Position the spacer and bracket (3), as shown. Install the six bolts and the washer.
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     Illustration 79	g03329372

141. Use Tool (R) (not shown) in order to ensure that the clutch pistons are free in the clutch housings:

     1. Put dry shop air pressure into each of the seven oil passages. The shop air pressure must have a pressure of 690 to 1030 kPa (100.1 to 149.4 psi).

     2. If the clutch pistons do not move, put a small amount of clean SAE 30 oil in each oil passage. Check the clutch pistons for movement. If the clutch pistons do not move, the transmission planetary must be disassembled.

End By:

1. Install the transmission hydraulic control. Refer to Disassembly and Assembly, "Transmission Hydraulic Control - Remove".

2. Connect the transfer gears to the transmission. Refer to Disassembly and Assembly, "Transmission Planetary and Transfer Gears - Connect".