784C and 785C Off-Highway Truck Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before the assembly procedure, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble.

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	g00494202

3. Heat ring carrier (67), ball bearing (68), and ring carrier (65) to a maximum temperature of 135°C (275°F). Install ring carrier (67), ball bearing (68), and ring carrier (65) onto output shaft (31).

4. Install two ring seals (64) onto ring carrier (67). Install ring seal (66) onto ring carrier (65).
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   Illustration 2	g00494747

5. Heat inner bearing (69) to a maximum temperature of 135°C (275°F). Install inner bearing (69) onto stator carrier (56).

6. Install retaining ring (70) onto stator carrier (56).
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   Illustration 3	g00494681

7. Position stator carrier (56), as shown. Install Tool (E) to the end of output shaft (31). Attach Tool (E) to a suitable lifting device and a hoist. Use Tool (E) and the hoist in order to position output shaft (31) into stator carrier (56). The weight of output shaft (31) is 25 kg (55 lb).

8. Remove Tool (E) from the end of output shaft (31).
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   Illustration 4	g00494712

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   NOTICE
   Make sure that the oil passages in the fluid distributor are aligned with the fluid passages in the stator carrier. Failure to align the fluid passages may damage the torque converter.

9. If necessary, install O-ring plug (63) and the O-ring seal onto fluid distributor (61).

10. Install lip seal (62) into fluid distributor (61). Refer to Reuse and Salvage Guidelines, "Lip Type Seals"SEBF9247 for the proper lip seal installation procedure.

    Note: Make sure that the lip of the lip seal is down. Lubricate the sealing lip lightly with the lubricant that is being sealed.

11. Use 11 bolts (60) to install fluid distributor (61) and the gasket onto stator carrier (56). Tighten 11 bolts (60) to a torque 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 5	g00494123

12. Position yoke (59) onto the output shaft. Install bolt (57), retainer (58) and the O-ring seal. Tighten bolt (57) to a torque of 240 ± 25 N·m (175 ± 20 lb ft).
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    Illustration 6	g00494080

13. Rotate stator carrier (56). Install two ring seals (55) onto stator carrier (56).

14. Position freewheel race (53) and split washer (54) onto stator carrier (56).

15. Use six bolts (52) to install split washer (54) and freewheel race (53) to stator carrier (56). Tighten six bolts (52) to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
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    Illustration 7	g00494822

16. Use eight twelve point bolts (50) to install pump drive gear (49) to converter impeller assembly (41). Tighten eight twelve point bolts (50) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 8	g00494017

17. Position converter impeller assembly (41) onto housing (7). Install 24 bolts (48) and the washers. Hand tighten 24 bolts (48).
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    Illustration 9	g00494840

18. Position converter impeller assembly (41), as shown. Lower the temperature of wear sleeve (51) to a temperature of −40°C (−40°F). Use Tooling (B) (not shown) to install wear sleeve (51) into the bore of converter impeller assembly (41).
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    Illustration 10	g00495825

19. Use eight bolts (43) to install impeller hub assembly (44) to converter impeller assembly (41). Tighten eight bolts (43) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

20. Install wear sleeve (45) and thrust race (46) onto impeller hub assembly (44).

21. Apply 4C-4030 Thread Lock Compound to the threads of two hex socket screws (47). Install two hex socket screws (47) and the retaining washers.
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    Illustration 11	g00494017

22. Position housing (7) and converter impeller assembly (41), as shown. Tighten 24 bolts (48) to a torque of 80 ± 10 N·m (59 ± 7 lb ft).
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    Illustration 12	g00493823

23. Position housing (7), as shown. Install Tooling (A) to housing (7). Attach Tooling (A) to a suitable lifting device and a hoist. Use Tooling (A) and the hoist to position housing (7) and converter impeller assembly (41) onto output shaft (31). The weight of housing (7) and converter impeller assembly (41) as an assembly is 80 kg (176 lb).

24. Remove Tooling (A) from housing (7).
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    Illustration 13	g00494885

25. Install thrust bearing (42).
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    Illustration 14	g00559412

26. Install retaining ring (35) into converter stator (32).

27. Rotate converter stator (32). Lower the temperature of freewheel cam (40) to a temperature of −40°C (−40°F). Raise the temperature of converter stator (32) to a maximum temperature of 135°C (275°F).

28. Use Tooling (B) (not shown) to install freewheel cam (40) into converter stator (32), as shown.
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    Illustration 15	g00559423

29. Install side plate (39) into converter stator (32). Stake two opposite teeth of side plate (39) to hold side plate (39) in position.
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    Illustration 16	g00559448

30. Position converter stator (32), as shown. Install roller cage (37) into converter stator (32), as shown. Install two new springs (38).

    Note: Only new springs (38) should be used.

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    Illustration 17	g00494889

31. Install 22 freewheel rollers (36) into roller cage (37).

    Note: Apply 1P-0808 Multipurpose Grease to freewheel rollers (36) to hold freewheel rollers (36) in position.

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    Illustration 18	g00494900

32. Install side plate (34) onto converter stator (32).

33. Install retaining ring (35) onto converter stator (32).
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    Illustration 19	g00493762

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    Illustration 20	g00493753

34. Install converter stator (32) and thrust bearing (33) onto output shaft (31), as shown.

    Note: The converter stator should only rotate in the clockwise direction.

35. Use Tool (C) to install retaining ring (30) onto output shaft (31).
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    Illustration 21	g00494972

36. Install sleeve bearing (27) into turbine hub assembly (26).

37. Install sleeve (28) and thrust race (29) into turbine hub assembly (26).
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    Illustration 22	g00495054

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    Illustration 23	g00493639

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    Illustration 24	g00495256

38. Install turbine hub assembly (26) onto converter turbine (25). Use two 1/2 inch - 13 NC guide bolts (X) to align the splines of turbine hub assembly (26) with the splines of converter turbine (25).

39. Position converter turbine (25), as shown. Use six bolts (24) to install clutch hub (20) onto converter turbine (25).

40. Remove two 1/2 inch - 13 NC guide bolts (X).

41. Install ring carrier (22) and race (23) onto converter turbine (25).

42. Install seal ring (21) onto ring carrier (22).

43. Install Tooling (D) to converter turbine (25). Attach Tooling (D) to a suitable lifting device and a hoist. Use Tooling (D) and the hoist to install converter turbine (25) onto housing (7). The weight of converter turbine is 34 kg (75 lb).

44. Remove Tooling (D) from converter turbine (25). Install the remaining two bolts (24) to clutch hub (20). Tighten eight bolts (24) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).
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    Illustration 25	g00493626

45. Install ball bearing (18) and wear sleeve (17) into clutch carrier (3).

46. Install seal ring (19) onto clutch carrier (3). Install seal ring (16) onto lockup clutch piston (15).
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    Illustration 26	g00493625

    Note: Two bolts (1) may be installed to provide a lifting point for the lockup clutch piston.

47. Install lockup clutch piston (15) into clutch carrier (3).
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    Illustration 27	g00493623

48. Install three friction discs (13) and two clutch plates (14) into clutch carrier (3).

    Note: Start with a friction disc. Alternate the friction discs and the clutch plates.

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    Illustration 28	g00495384

49. Install backing plate (10) into clutch carrier (3). Use 12 bolts (12) to install four split washers (11). Tighten 12 bolts (12) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 29	g00507749

50. Position clutch carrier (3), as shown. Install Tooling (A) to clutch carrier. Attach Tooling (A) to a suitable lifting device and a hoist. Use Tooling (A) and the hoist to install clutch carrier (3) onto housing (7), as shown. The weight of clutch carrier (3) is 104 kg (229 lb).

    Note: The internal splines of the friction discs will need to be aligned with the clutch hub that is on the turbine assembly.

51. Remove Tooling (A) from clutch carrier (3).
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    Illustration 30	g00495482

52. Install 24 bolts (6) to install clutch carrier (3) to the housing. Tighten 24 bolts (6) to a torque of 240 ± 25 N·m (175 ± 20 lb ft).

53. Use a brass drift to ensure that wear sleeve (17) and ball bearing (18) are fully seated.
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    Illustration 31	g00495526

54. Use three bolts (4) to install retainer (5) to the end of the output shaft. Tighten three bolts (4) to a torque of 25 N·m (18 lb ft).

    Note: Do not install the O-ring seal and the shims now.

55. Remove three bolts (4) and retainer (5).
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    Illustration 32	g00495491

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    Illustration 33	g00495531

56. Use a depth micrometer to measure the distance from the top of ball bearing (18) to the top of output shaft (31). Record this measurement.

57. Use the measurement that was recorded in Step 56 to determine the thickness of shim pack (71). Use a micrometer to assemble shim pack (71) so that there is a total gap of .005 mm (0.0002 inch) to .13 mm (0.0051 inch).

58. Position shim pack (71) onto the end of output shaft (31).
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    Illustration 34	g06365711

59. Use three bolts (4) to install retainer (5) and the O-ring seal to the end of the output shaft. Tighten three bolts (4) to a torque of 120 ± 15 N·m (89 ± 11 lb ft). Install pipe plug (8) and orifice plug (9).
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    Illustration 35	g00493378

60. Use 12 bolts (1) to install flywheel pilot (2) to clutch carrier (3). Tighten 12 bolts (1) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).

End By:

1. Install the torque converter.