797 Off-Highway Truck Power Train Caterpillar

Transmission Planetary - Assemble

Usage:

797 5YW

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	202-2056	Shipping Stand	1
B	138-7574	Link Bracket	4
C	138-7575	Link Bracket	1
D	138-7573	Link Bracket	3
E	1P-1853	Retaining Ring Pliers	1
F	138-7576	Link Bracket	4
J	1P-1863	Retaining Ring Pliers	1
K	136-1452	Retaining Ring Pliers As	1
L	3E-3879	Eyebolt	1
N	1P-2420	Transmission Repair Stand	1
	FT-0996	Positioning As	4
	Ft-0957	Positioning As	4
P	FT-3108	Plate	1
S	1D-4595	Bolt	3
S	1D-5118	Nut	3
U	9S-9152	Bearing Puller Gp	1
X	1P-0520	Driver Gp	1
Y	1P-0510	Driver Gp	1
Z	-	Loctite 242	-
AA	-	Loctite High Flex Form in Place Gasket	-
BB	466-7458	Seal Installer	1
CC	-	Loctite 515 Gasket Eliminator Flange Sealant	-
DD	314-8478	Diagonal Cutter	1
EE	-	Loctite 518	-

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Illustration 1	g01429640

Raise the temperature of bearing (337). Install bearing (337) onto input shaft (332).
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Illustration 2 g01429661
Attach Tooling (U) onto input shaft (332). Attach Tooling (D) and a suitable lifting device to Tooling (U). Use Tooling (U), Tooling (D), and the suitable lifting device to position input shaft (332) to Tooling (P) and Tooling (N) (not shown). Rest input shaft (332) on the ground and remove the suitable lifting device. The weight of input shaft (332) is approximately 59 kg (130 lb).
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Illustration 3 g01429647
Attach Tooling (B) and a suitable lifting device to clutch housing (335). Position clutch housing (335) onto Tooling (N) and Tooling (P). The weight of clutch housing (335) is approximately 118 kg (260 lb). Install plugs (336) and the O-ring seals to clutch housing (335). Tighten plugs (336) to a torque of 300 ± 30 N·m (221 ± 22 lb ft).
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Illustration 4 g01429136

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Illustration 5 g01429731
Attach a suitable lifting device to Tooling (D). Use Tooling (U), Tooling (D), and the suitable lifting device to position input shaft (332) to clutch housing (335). Use Tooling (K) to install retaining ring (334).
Install O-ring seal (333).
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Illustration 6 g01429196
Install toric ring (331) to ring carrier (329). Use Tooling (BB) Install lip seal (330) to ring carrier (329). Refer to Reuse and Salvage Guidelines, "Lip Type Seals"SEBF9247 for the proper lip seal installation procedure.
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Illustration 7 g01429159
Apply Tooling (CC) onto the outside toric ring and the inside lip seal prior to installing ring carrier (329). Position ring carrier (329) and install bolts (328). Tighten bolts (328) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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Illustration 8 g01429123
Install seal rings (327) and seal ring (326) to ring carrier assembly (324).
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Illustration 9 g01429028
Position ring carrier assembly (324) and install bolts (325). Tighten bolts (325) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 10 g01428990
Install seal ring (322) to clutch housing (320).
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Illustration 11 g01428942

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Illustration 12 g01429845
Attach Tooling (C) and a suitable lifting device to clutch housing (320). Position clutch housing (320). The weight of clutch housing (320) is approximately 50 kg (111 lb).
Install bearing (323). Install retaining ring (321).
Note: Be sure that the slot in bearing (323) aligns with the dowel in the ring carrier.
Use Tooling (C) and the suitable lifting device to raise clutch housing (320). Be sure that clutch housing (320) seats against bearing (323).
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Illustration 13 g01428929

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Illustration 14 g01429958
Install seal ring (319) to clutch piston (318).
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Illustration 15 g01502026

Note: Hub (317), sun gear (287), and bearing carrier (286) have four missing interior splines in each part. Be sure to align the missing splines on sun gear (287) with the missing splines on hub (317) during the assembly process. Be sure to align the missing splines on bearing carrier (286) with the missing splines on sun gear (287) during the assembly process. Alignment of the missing splines is required to lubricate the interior parts of the transmission.
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Illustration 16 g01428902
Position clutch piston (318). Install hub (317). Refer to Illustration 15. Install springs (316) and dowels (315).
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Illustration 17 g01428886

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Illustration 18 g01429961
Install seal ring (314) to clutch piston (313).
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Illustration 19 g01429963

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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.
Position clutch piston (313). Install bolts (310) and install bolts (312). Tighten bolts (310) and bolts (312) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Install thrust disc (311).
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Illustration 20 g01430085
Use Tooling (X) to install sleeve bearing (309) into ring gear (306).
Note: Be sure that Surface (A) of sleeve bearing (309) is installed 1.0 ± 0.5 mm (0.04 ± 0.02 inch) below Surface (B) of ring gear (306).
Note: Be sure that the inside diameter of sleeve bearing (309) measures 122.350 ± 0.039 mm (4.8169 ± 0.0015 inch) after sleeve bearing (309) is installed.
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Illustration 21 g01428803
Install ring gear (306). Install clutch plates (307) and four friction discs (308) (not shown).
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Illustration 22 g01428798
Position end plate (305) and install bolts (304). Tighten bolts (304) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
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Illustration 23 g01428779
Install plate assembly (303).
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Illustration 24 g01428764

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Illustration 25 g03569310
Install bearings (301) into gear (302). Install gear (302) and thrust discs (300) into carrier assembly (283). Install shaft (299) into carrier assembly (283). Install spring pin (298) even with Counter Bore (X) to secure shaft (299) into carrier assembly (283). Repeat this step for the three remaining planetary gears.
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Illustration 26 g01426729

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Illustration 27 g03569356
Install bearings (296) into gear (297). Install gear (297) and thrust discs (295) into carrier assembly (283). Install shaft (293) into carrier assembly (283). Install spring pin (294) even with Counter Bore (X) to secure shaft (293) into carrier assembly (283). Repeat this step for the three remaining planetary gears.
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Illustration 28 g01426726
Install thrust buttons (292) to coupling (291).
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Illustration 29 g01426700

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Illustration 30 g01426693
Position coupling (291) onto carrier assembly (283) over suitable cribbing. Compress lock ring (290). Raise coupling (291) until lock ring (290) snaps into position on carrier assembly (283) and coupling (291).
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Illustration 31 g01429981
Attach Tooling (D) and a suitable lifting device to carrier assembly (283) to install carrier assembly (283). The weight of carrier assembly (283) is approximately 77 kg (170 lb).
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Illustration 32 g01426680
Install O-ring seal (288) onto sun gear (287).
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Illustration 33 g01502026

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Illustration 34 g01429996
Install sun gear (287). Be sure that missing Splines (M) are aligned with the missing splines in hub (317) (not shown). Refer to Illustration 33.
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Illustration 35 g01430004
Install seal rings (289) onto bearing carrier (286).
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Illustration 36 g01502026

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Illustration 37 g01430008
Install bearing carrier (286). Be sure that missing Splines (N) are aligned with the missing splines in sun gear (287) (not shown). Refer to Illustration 36.
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Illustration 38 g01430024
Install bearing (285) and install retaining ring (284).
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Illustration 39 g01426610
Install dowels (280), clutch plates (282), and friction discs (281).
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Illustration 40 g01426505

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Illustration 41 g01430055
Install seal ring (278) and seal ring (279) onto clutch piston (276). Repeat this step for clutch piston (277) (not shown).
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Illustration 42 g01426496
Install clutch piston (277) (not shown) and clutch piston (276) into clutch housing (273).
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Illustration 43 g01426477
Position clutch plate (274) to clutch housing (273). Install Tooling (S) to hold clutch plate (274) to clutch housing (273) during the assembly process.
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Illustration 44 g01426469

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Illustration 45 g01431496
Attach Tooling (C) and a suitable lifting device to clutch housing (273). The combined weight of clutch housing (273) and clutch plate (274) is approximately 132 kg (290 lb). Position clutch housing (273) and clutch plate (274) to be located within approximately 25 mm (1.0 inch) of plate assembly (303). Install springs (275). Finish lowering clutch housing (273) and clutch plate (274) into position.
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Illustration 46 g01426455

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Illustration 47 g01426427
Remove Tooling (S) that secured clutch plate (274) to clutch housing (273). Install 17 bolt dampers (272) (not shown). Install dowels (271).
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Illustration 48 g01426403
Attach Tooling (D) and a suitable lifting device to ring gear (270) to install ring gear (270). The weight of ring gear (270) is approximately 45 kg (100 lb).
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Illustration 49 g01426399
Install clutch plate (269).
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Illustration 50 g01426390
Install clutch plates (267) and four friction discs (268) (not shown).
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Illustration 51 g01430846

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Illustration 52 g01426371

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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.
Attach Tooling (B) and a suitable lifting device to plate (265). The weight of plate (265) is approximately 91 kg (200 lb). Position plate (265) to be located within approximately 25 mm (1.0 inch) of clutch housing (273). Install springs (266). Finish lowering plate (265) into position. Install bolts (264). Tighten bolts (264) to a torque of 460 ± 60 N·m (340 ± 44 lb ft).
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Illustration 53 g01426331
Install sun gear (263).
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Illustration 54 g01426315

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Illustration 55 g03569357
Install bearings (259) into gear (260). Install gear (260) and thrust discs (258) into carrier assembly (254). Install shaft (261) into carrier assembly (254). Install spring pin (262) even with Counter Bore (X) to secure shaft (261) into carrier assembly (254). Repeat this step for the remaining planetary gears.
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Illustration 56 g01430289
Use Tooling (X) and a suitable press to install bearing carrier (255) onto bearing (257).
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Illustration 57 g01430283
Attach Tooling (D) and a suitable lifting device to carrier assembly (254) to install carrier assembly (254). The weight of carrier assembly (254) is approximately 73 kg (160 lb).
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Illustration 58 g01430291
Install bearing (257) and bearing carrier (255) as one unit onto carrier assembly (254). Install retaining ring (256).
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Illustration 59 g01426257
Use two people to install ring gear (253). The weight of ring gear (253) is approximately 32 kg (70 lb). Position lock plates (252) and install new bolts (251). Tighten bolts (251) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 60 g01426244
Install sun gear (250) and install retaining ring (249).
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Illustration 61 g01426235

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Illustration 62 g03569358
Install bearings (247) into gear (248). Install gear (248) and thrust discs (246) into carrier assembly (243). Install shaft (244) into carrier assembly (243). Install spring pin (245) even with Counter Bore (X) to secure shaft (244) into carrier assembly (243). Repeat this step for the remaining planetary gears.
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Illustration 63 g01426229
Attach Tooling (D) and a suitable lifting device to position carrier assembly (243). The weight of carrier assembly (243) is approximately 91 kg (200 lb).
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Illustration 64 g01430381
Position rotor (242). Install bolts (241). Tighten bolts (241) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 65 g01426190
Install bearing (240) into housing (235). Install retaining ring (239).
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Illustration 66 g01430326
Attach Tooling (B) and a suitable lifting device to housing (235) to position housing (235). The weight of housing (235) is approximately 159 kg (350 lb). Be sure that the dowel in carrier assembly (243) is aligned with the notch in bearing (240) (not shown). Install bolts (236). Tighten bolts (236) to a torque of 460 ± 60 N·m (340 ± 44 lb ft).
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Illustration 67 g01426084
Install seal rings (238) onto carrier (237).
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Illustration 68 g01430377

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Illustration 69 g01430643

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Illustration 70 g01430663
Attach Tooling (D) and a suitable lifting device to carrier assembly (243). The weight of carrier assembly (243) is approximately 91 kg (200 lb). Raise carrier assembly (243) until carrier assembly is fully seated against bearing (240) (not shown). Position suitable prybars against ring gear (253) and carrier assembly (243) to keep carrier assembly (243) raised in position. Remove Tooling (D) and the suitable lifting device.
Note: Be sure that the dowel in carrier assembly (243) is aligned with the notch in bearing (240). Ensure that carrier assembly (243) is fully seated.
Install carrier (237). Install plate (234) and install bolts (233). Tighten bolts (233) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 71 g01430677
Attach speed sensor (232) to input planetary (230). Tighten speed sensor (232) to a torque of 37 ± 4 N·m (27 ± 3 lb ft).
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Illustration 72 g01425120

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Illustration 73 g01425119
Attach Tooling (B) and a suitable lifting device to input planetary (230) to install input planetary (230) into case (231). The weight of input planetary (230) is approximately 1134 kg (2500 lb). The technician will need to rotate input planetary (230) in a counterclockwise direction to install input planetary (230) into case (231).
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Illustration 74 g01425117
Install bolts (229) that hold input planetary (230) to input case assembly (100). Tighten bolts (229) to a torque of 460 ± 60 N·m (340 ± 44 lb ft).
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Illustration 75 g06305529
Apply Tooling (EE) to the sleeve manifold (228) before installation.
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Illustration 76 g01425105
Position sleeve manifold (228) and install bolts (227). Tighten bolts (227) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
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Illustration 77 g01424082
Position ring carrier (226). Install bolts (225). Tighten bolt (225) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Install seal rings (224).
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Illustration 78 g01425200
Attach Tooling (D) and a suitable lifting device to clutch housing (220). Install clutch housing (220). The weight of clutch housing (220) is approximately 95 kg (210 lb).
Install bearing (222). Install retaining ring (221) and install seal ring (223).
Note: Be sure that the slot in bearing (222) aligns with the dowel in ring carrier (226).
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Illustration 79 g01423977
Install seal ring (219) to clutch piston (217).
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Illustration 80 g01423963
Install dowels (218) and install clutch piston (217).
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Illustration 81 g01423953

Your transmission may be equipped with coil springs (216), as shown.

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Illustration 82 g01423944

Your transmission may be equipped with a wave spring (215), as shown.
Install springs (216) or install wave springs (215).
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Illustration 83 g01423935
Install seal ring (214) to piston (213).
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Illustration 84 g01425217

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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.
Position piston (213). Install bolts (212). Tighten bolts (212) evenly to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 85 g01423876
Install carrier ring (209). Install pin (211). Install seal ring (210).
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Illustration 86 g01430170
If necessary, apply Tooling (Z) to orifice setscrew (208). Install orifice setscrew (208) to shaft (184). Tighten orifice setscrew (208) to a torque of 105 ± 20 N·m (75 ± 15 lb ft).
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Illustration 87 g01430219
If necessary, apply Tooling (Z) to orifice plug (206). Install orifice plug (206) to shaft (184). Tighten orifice plug (206) to a torque of 75 ± 15 N·m (55 ± 11 lb ft).
Use Tooling (Y) to install sleeve bearing (207) into shaft (184).
Note: Be sure that Surface (C) of sleeve bearing (207) is 6.0 ± 1.0 mm (0.24 ± 0.04 inch) below Surface (D) of shaft (184) when you are installing sleeve bearing (207).
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Illustration 88 g01423863
Install seal ring (205) and O-ring seal (204) onto shaft (184).
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Illustration 89 g01423696

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Illustration 90 g01423544
Attach Tooling (L) to shaft (184). Install shaft (184). The weight of shaft (184) is approximately 100 kg (220 lb). Reference the Disassembly and Assembly, "Transmission Planetary - Disassembly" Step 107 for the proper amount of cribbing under shaft (184).
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Illustration 91 g01425241

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Illustration 92 g01425252
Position hub (203) onto sun gear (203A) over suitable cribbing. Compress lock ring (202). Raise hub (203) until lock ring (202) snaps into position on sun gear (203A) and hub (203).
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Illustration 93 g01423652
Install seal rings (201) onto sun gear assembly (199).
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Illustration 94 g01423628
Attach Tooling (D) and a suitable lifting device to sun gear assembly (199). Install sun gear assembly (199). The weight of sun gear assembly (199) is approximately 54 kg (120 lb). Install clutch plate (200).
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Illustration 95 g01423619
Install four friction discs (198) (not shown) and clutch plates (197).
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Illustration 96 g01423605

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Illustration 97 g03569362
Install bearings (195) into gear (196). Install gear (196) and thrust discs (194) into carrier assembly (188). Install shaft (192) into carrier assembly (188). Install spring pin (193) even with Counter Bore (X) to secure shaft (192) into carrier assembly (188). Repeat this step for the remaining planetary gears.
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Illustration 98 g01423561

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Illustration 99 g01425310
Attach Tooling (D) and a suitable lifting device to carrier assembly (188). Position carrier assembly (188). The weight of carrier assembly (188) is approximately 122 kg (270 lb). Install bolts (189). Tighten bolts (189) to a torque of 240 ± 40 N·m (175 ± 30 lb ft).
Reduce temperature of bearing (191) . Install bearing (191). Use Tooling (K) to install retaining ring (190).
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Illustration 100 g01423520
Lower temperature of bearing retainer (187). Install bearing retainer (187) onto shaft (184). Install sun gear (186) onto shaft (184). Install retaining ring (185).
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Illustration 101 g01423456

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Illustration 102 g01423435
Attach Tooling (B) and a suitable lifting device to housing assembly (183). Position housing assembly (183). Install bolts (181). Tighten bolts (181) to a torque of 240 ± 40 N·m (175 ± 30 lb ft). Install plugs (182) and the O-ring seals. Tighten plugs (182) to a torque of 17 ± 2 N·m (150 ± 17 lb in).
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Illustration 103 g01425358
Install seal rings (180) onto clutch piston (178).
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Illustration 104 g01423418
Attach Tooling (D) and a suitable lifting device to clutch piston (178) to install clutch piston (178). Use two people to install ring gear (179). The weight of ring gear (179) is approximately 32 kg (70 lb).
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Illustration 105 g01423411
Install dowels (177) and clutch plate (176).
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Illustration 106 g01423379
Install friction discs (175) and separator springs (173). Install clutch plates (172) and springs (174).
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Illustration 107 g01425449
Install seal rings (171) onto clutch piston (166).
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Illustration 108 g01423233
Use a suitable lifting device to install ring gear (165) to housing assembly (167). The weight of ring gear (165) is approximately 122 kg (270 lb). Attach Tooling (D) and a suitable lifting device to clutch piston (166). Install clutch piston (166) to housing assembly (167). The weight of clutch piston (166) is approximately 27 kg (60 lb).
Install bolt dampers (170) to housing assembly (167).
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Illustration 109 g01423119

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Illustration 110 g01423094
Attach Tooling (B) and a suitable lifting device to housing assembly (167) to position housing assembly (167), ring gear (166), and clutch piston (166) as one unit. The combined weight of housing assembly (167), ring gear (166), and clutch piston (166) is approximately 367 kg (810 lb). Position lock plates (169). Install new bolts (168) and the new washers. Tighten bolts (168) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 111 g01423086
Install dowels (163) and clutch plate (164) to output planetary (106).
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Illustration 112 g01423071
Install friction discs (162) and separator springs (161). Install clutch plates (160).
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Illustration 113 g01423055

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Illustration 114 g01423048

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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.
Install springs (159) to output planetary (106). Attach Tooling (B) and a suitable lifting device to plate assembly (158). The weight of plate assembly (158) is approximately 82 kg (180 lb). Position plate assembly (158) and install bolts (157). Tighten bolts (157) to a torque of 800 ± 100 N·m (600 ± 75 lb ft).
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Illustration 115 g01423028

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Illustration 116 g03567027
Install bearings (155) into gear (156). Install gear (156) and thrust discs (154) into carrier assembly (149). Install shaft (152) into carrier assembly (149). Install spring pin (153) even with Counter Bore (X) to secure shaft (152) into carrier assembly (149). Repeat this step for the remaining planetary gears.
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Illustration 117 g01423008

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Illustration 118 g01423013
Attach Tooling (C) and a suitable lifting device to output shaft assembly (148). The weight of output shaft assembly (148) is approximately 122 kg (270 lb). Position output shaft assembly (148) to carrier assembly (149).
Install retaining ring (151) and install spring pins (150).
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Illustration 119 g01423002
Use Tooling (C) and the suitable lifting device to install output shaft assembly (148) and carrier assembly (149) to output planetary (106). The combined weight of output shaft assembly (148) and carrier assembly (149) is approximately 290 kg (640 lb).
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Illustration 120 g01422528
Install bearing (147) onto output planetary (106). Use Tooling (J) to install retaining ring (146).
Note: Be sure that the slot in bearing (147) aligns with the dowel in the shaft.
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Illustration 121 g01422526
Position bearing cap (145) and install bolts (144) to output planetary (106). Tighten bolts (144) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 122 g01425479

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Illustration 123 g01425531
Attach Tooling (D) and a suitable lifting device to hub (143) to position hub (143) onto sun gear (143A). Compress lock ring (142). Raise hub (143) until lock ring (142) snaps into position on sun gear (143A) and hub (143).
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Illustration 124 g01422474
Attach Tooling (D) and a suitable lifting device to hub assembly (141) to position hub assembly (141) to output planetary (106). The weight of hub assembly (141) is approximately 32 kg (70 lb). Install retaining ring (140) and retaining ring (139).
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Illustration 125 g01422472
Install bolt dampers (138) into clutch housing (137).
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Illustration 126 g01422449
Attach Tooling (B) and a suitable lifting device to clutch housing (137). Position clutch housing (137) to output planetary (106). The weight of clutch housing (137) is approximately 245 kg (540 lb).
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Illustration 127 g01425566
Install seal ring (136) and seal ring (135) onto clutch piston (134).
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Illustration 128 g01422444
Attach Tooling (D) and a suitable lifting device to clutch piston (134). Install clutch piston (134) onto output planetary (106). The weight of clutch piston (134) is approximately 27 kg (60 lb).
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Illustration 129 g01422408
Use a suitable lifting device to position ring gear (133) onto suitable cribbing in output planetary (106). Use suitable prybars to raise ring gear (133) and remove the suitable cribbing and the suitable lifting device. Lower ring gear (133) into position in output planetary (106). The weight of ring gear (133) is approximately 54 kg (120 lb).
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Illustration 130 g01422397

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Illustration 131 g03569366
Install bearings (131) into gear (132). Install gear (132) and thrust discs (130) into carrier assembly (123). Install shaft (128) into carrier assembly (123). Install spring pin (129) even with Counter Bore (X) to secure shaft (128) into carrier assembly (123). Repeat this step for the remaining planetary gears.
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Illustration 132 g01422382
Position oil slinger (127) and the ring onto carrier assembly (123). Install new bolts (126). Tighten bolts (126) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
Install ring carrier (124) and dowel (125) to carrier assembly (123).
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Illustration 133 g01422257
Attach Tooling (D) and a suitable lifting device to carrier assembly (123) to install carrier assembly (123) to output planetary (106). The weight of carrier assembly (123) is approximately 195 kg (430 lb).
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Illustration 134 g01422251
Install dowels (121) and install clutch plate (122).
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Illustration 135 g01422214
Install friction discs (120), separator springs (119), and clutch plates (118).
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Illustration 136 g01422208
Install springs (117). Attach Tooling (B) and a suitable lifting device to separator plate (116) to position separator plate (116) onto output planetary (106). The weight of separator plate (116) is approximately 77 kg (170 lb).
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Illustration 137 g01422154

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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.
Install bolts (115). Tighten bolts (115) to a torque of 800 ± 100 N·m (600 ± 75 lb ft).
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Illustration 138 g01422050
Install seal ring (114).
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Illustration 139 g01421757
Attach Tooling (C) and a suitable lifting device to retainer (113) to position retainer (113). The weight of retainer (113) is approximately 23 kg (51 lb).
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Illustration 140 g01421754
Install bolts (112). Tighten bolts (112) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
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Illustration 141 g01421751
Install plugs (111) and the O-ring seals into support housing (110). Tighten plugs (111) to a torque of 270 ± 25 N·m (200 ± 18 lb ft).
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Illustration 142 g01421745
Attach Tooling (B) and a suitable lifting device to support housing (110). Position support housing (110) onto output planetary (106). The weight of support housing (110) is approximately 236 kg (520 lb).
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Illustration 143 g01421741
Install bolts (109) that hold support housing (110) to output planetary (106). Tighten bolts (109) to a torque of 800 ± 100 N·m (590 ± 74 lb ft).
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Illustration 144 g01421622
Position manifold (108) onto output planetary (106). Install bolts (107). Tighten bolts (107) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 145 g01421616
Attach Tooling (B) and a suitable lifting device to output planetary (106). Position output planetary (106) to case (105). The weight of output planetary (106) is approximately 2957 kg (6520 lb).
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Illustration 146 g01421567
Install bolts (104). Tighten bolts (104) to a torque of 800 ± 100 N·m (590 ± 75 lb ft).
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Illustration 147 g01421536
Position drain assembly (102). Install bolts (103) and the washers. Tighten bolts (103) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Install cap (101) and the O-ring seal. Tighten cap (101) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
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Illustration 148 g01425809
Attach Tooling (F) and a suitable lifting device to output case assembly (99). Position output case assembly (99) to input case assembly (100). The weight of output case assembly (99) is approximately 3992 kg (8800 lb). Install bolts (98). Tighten bolts (98) to a torque of 1600 ± 200 N·m (1180 ± 150 lb ft).
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Illustration 149 g01430937
Attach a suitable lifting device to planetary transmission (1), as shown. Position planetary transmission (1) on Tooling (A). The weight of planetary transmission (1) is approximately 5897 kg (13000 lb).
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Illustration 150 g01421417
Install coil assembly (95) onto modulating valve (89). Install washer (96) and nut (97) onto modulating valve (89). Tighten nut (97) to a torque of 13.0 ± 1.5 N·m (115.06 ± 13.28 lb in).
Install connector (94) and the O-ring seals onto modulating valve (89). Tighten connector (94) to a torque of 14 ± 4 N·m (124 ± 35 lb in).
Repeat Step 130 and Step 131 for the remaining modulating valves (89).
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Illustration 151 g01421411
Install O-ring seals (93) onto sleeve (92). Repeat this step for the remaining sleeves (92).
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Illustration 152 g01421392
Install sleeves (92) to hydraulic control assembly (66). Tighten bolts (91).
Install drains (90) to hydraulic control assembly (66). Tighten drains (90) to a torque of 35.0 ± 8 N·m (26.00 ± 6 lb ft).
Position modulating valve (89) onto hydraulic control assembly (66) and install bolts (88). Repeat this step for the remaining modulating valves (89).
Connect harness assembly (56) to hydraulic control assembly (66).
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Illustration 153 g01421390
Install orifice plug (87) into spool (82).
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Illustration 154 g01421386
Install ball (84), spring (85), and retainer (86) into spool (82).
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Illustration 155 g01421376

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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.
Use Tooling (E) to install retaining ring (83) onto spool (82).
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Illustration 156 g01421369
Install spool (82) into relief valve (68).
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Illustration 157 g01421360
Install spring (80) and stop (81).
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Illustration 158 g01421354
Install O-ring seal (79) to relief valve (68).
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Illustration 159 g01421341
If necessary, install bolt (78) into cover (77). Be sure to install bolt (78) at the recorded length from the disassembly.
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Illustration 160 g01421337

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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.
Position cover (77) to relief valve (68). Install bolts (76). Tighten bolts (76) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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Illustration 161 g01421331
Install O-ring seal (75) to adjustment cover (74).
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Illustration 162 g01421325
Position adjustment cover (74) and install bolts (73). Tighten bolts (73) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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Illustration 163 g01421318
Install slug (72) into relief valve (68).
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Illustration 164 g01421314
Install O-ring seal (71) onto plug (70).
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Illustration 165 g01421312
Install plug (70). Tighten plug (70) to a torque of 225 ± 15 N·m (165 ± 11 lb ft).
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Illustration 166 g01421285
Install fittings (69) and the O-ring seals to relief valve (68). Tighten fittings (69) to a torque of 35 ± 3 N·m (26 ± 2 lb ft).
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Illustration 167 g01421279
Position relief valve (68) onto hydraulic control assembly (66). Install bolts (67).
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Illustration 168 g01421271
Attach a suitable lifting device to hydraulic control assembly (66). The weight of hydraulic control assembly (66) is approximately 34 kg (75 lb). Use the suitable lifting device to position hydraulic control assembly (66) to the transmission. Be sure that the sleeves are engaged into the transmission.
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Illustration 169 g01421268
Install bolts (65). Tighten bolts (65) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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Illustration 170 g01421266

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Illustration 171 g01421254
Position tube assembly (63). Connect fitting (64) and fitting (62).
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Illustration 172 g01421249
Install O-ring seals (61) onto sleeve (60).
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Illustration 173 g01421240
Install sleeve (60).
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Illustration 174 g01421224
Position solenoid connector (14). Position the plate and install bolts (59). Tighten bolts (59) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Install nut (58).
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Illustration 175 g01421223
Install bolts (57). Connect harness assembly (56).
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Illustration 176 g01421200
Install hose assemblies (55). Tighten hose assemblies (55) to a torque of 25 ± 3 N·m (18 ± 2 lb ft).
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Illustration 177 g01420725
Attach Tooling (D) and a suitable lifting device to cover (54). Install the gasket and cover (54). The weight of cover (54) is approximately 45 kg (100 lb).
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Illustration 178 g01420714
Install bolts (53) to cover (54). Tighten bolts (53) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 179 g01420694

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Illustration 180 g01431576
Apply Tooling (AA) to the mating surface of housing assembly (48). Be sure to wipe off any excess Tooling (AA) from the surface of housing assembly (48). Attach Tooling (D) and a suitable lifting device to housing assembly (48). The weight of housing assembly (48) is approximately 32 kg (71 lb). Position housing assembly (48) and install bolts (52). Tighten bolts (52) to a torque of 240 ± 40 N·m (175 ± 30 lb ft).
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Illustration 181 g01420678
Install screen assemblies (51) and magnetic screen assemblies (50) into housing assembly (48).
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Illustration 182 g01420675
Install O-ring seals (49) to cover (47).
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Illustration 183 g01420666
Position cover (47) to housing assembly (48). Install nuts (46).
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Illustration 184 g01420662
Install O-ring seals (45) onto sleeve (44).
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Illustration 185 g01420659
Install sleeve (44).
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Illustration 186 g01420652
Install O-ring seal (43) to filter assembly (42).
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Illustration 187 g01420638

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Illustration 188 g01420611
Attach Tooling (C) and a suitable lifting device to filter assembly (42). The weight of filter assembly (42) is approximately 68 kg (150 lb). Position filter assembly (42) and install bolts (41). Tighten bolts (41) to a torque of 240 ± 40 N·m (175 ± 30 lb ft). Remove Tooling (C) and the suitable lifting device. Install bolt (40). Tighten bolt (40) to a torque of 240 ± 40 N·m (175 ± 30 lb ft). If necessary, install differential switch (13). Tighten differential switch (13) to a torque of 30 ± 3 N·m (22 ± 2 lb ft).
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Illustration 189 g01420604
Install O-ring seals (39) onto sleeve (38).
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Illustration 190 g01420582
Install sleeve (38).
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Illustration 191 g01420595
Install O-ring seal (37) to manifold (36).
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Illustration 192 g01420543
Position manifold (36) and install bolts (35). Tighten bolts (35) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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Illustration 193 g01420537
Install O-ring seals (34) onto sleeves (32).
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Illustration 194 g01420532
Install O-ring seals (33) onto sleeves (31).
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Illustration 195 g01420501
Install sleeves (32) and sleeves (31).
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Illustration 196 g01420505

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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.
Install valve (29) into valve assembly (25). Install washers (28) and spring (27). Install cap (26). Tighten cap (26) to a torque of 41 ± 7 N·m (30 ± 5 lb ft). Install O-ring seal (30).
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Illustration 197 g01420485
Install valve assembly (25) to relief valve (19). Tighten valve assembly (25) to a torque of 41 ± 7 N·m (30 ± 5 lb ft). Install O-ring seal (30). Install O-ring seal (24) and O-ring seals (23). Install O-ring seals (22).
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Illustration 198 g01420327
Position relief valve assembly (19). Install bolts (18). Tighten bolts (18) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
Position hose assembly (20) and install bolts (21). Tighten bolts (21) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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Illustration 199 g01420214
Install adapter assembly (17) and the O-ring seal. Tighten adapter assembly (17) to a torque of 34 ± 3 N·m (25 ± 2 lb ft).
Install pressure sensor (8) and the O-ring seal. Tighten the connector on pressure sensor (8) to a torque of 10 ± 2 N·m (90 ± 18 lb in).
Position clips (15) and install bolts (16). Tighten bolts (16) to a torque of 100 ± 20 N·m (75 ± 15 lb ft).
Install oil pressure sensor (10).
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Illustration 200 g01420175
Position harness assembly (9) and install bolts (12). Connect solenoid connector (14) to harness assembly (9). Connect differential switch (13) to harness assembly (9).
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Illustration 201 g01420181
Use Tooling (DD) to install lockwire (11).
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Illustration 202 g01419905
Connect oil temperature sensor (10) to harness assembly (9). Connect pressure sensor (8) to harness assembly (9). Install bolts (7).
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Illustration 203 g01419893
Install seal ring (6) onto yoke (2).
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Illustration 204 g01419886

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Illustration 205 g01419841
Attach Tooling (B) and a suitable lifting device to yoke (2). The weight of yoke (2) is approximately 45 kg (100 lb). Position yoke (2). Install O-ring seal (5). Position plate (4) and install bolt (3). Tighten bolt (3) to a torque of 530 ± 70 N·m (390 ± 50 lb ft).