966F Series II Wheel Loader Power Train Caterpillar

Installation Procedure

Note: Cleanliness is an important factor. Before assembly, 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 and may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Note: If you heat the bearing cones, allow the parts to reach a uniform temperature. Then use a driver or a press to reset the bearing cones. Heat the bearing cones to a maximum of 135°C (275°F) for a maximum of four hours. Lubricate the bearing cones with SAE 30W gear oil after the bearing cones have cooled to prevent rust on the bearing cones.

Note: If you freeze the bearing cups, allow the parts to reach a uniform temperature. Then use a driver or a press to reset the bearing cups. The limit for freezing the bearing cups is −29°C (−20°F). Remove any frost and wipe the bearing cups dry. Lubricate the bearing cups with SAE 30W gear oil to prevent rust on the bearing cups.

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Illustration 1	g00337029

1. Raise the temperature of bevel gear (25). Do not heat the bevel gear for more than four hours. Install bevel gear (25) on differential assembly (11).

2. Use the following steps to install two spring assemblies (23):

   1. Install the large spring pin assembly partially into the bevel gear.

   2. Install the small spring assembly into the large spring pin assembly.

   3. Press the pins into bevel gear (22). Make sure that the pins are flush with the surface of bevel gear (25).

3. Apply Tooling (H) to bolts (24) and to the washer face. Install the washers and bolts (24) that hold bevel gear (25) in position. The torque for bolts (24) is 285 ± 40 N·m (210 ± 30 lb ft). Turn each bolt by an additional 120 ± 5 degrees. Make sure that the bevel gear is seated on the mating surface.
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   NOTICE
   A new differential group or a new case assembly will be equipped with bolts and washers used for shipping, assembly, and storage purposes only. Remove and discard these bolts and washers after the bevel gear has been installed. These bolts and washers should not be used for final assembly.

4. Raise the temperature of bearing cone (22).

5. Remove bolts (1) and the washers. Discard these bolts and washers.

6. Press bearing cone (22) on the differential assembly.
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   Illustration 2	g01001887

7. Press bearing cone (21) on the differential assembly.
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   Illustration 3	g00337026

8. Install bearing cup (19), sleeve assembly (18), and locating pin (17) in differential housing (20).

9. Apply lubricant to the threads on adjusting nut (16). Install adjusting nut (16) in differential housing (20). Do not install bolt lock (15) and bolt (14) at this time.
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   Illustration 4	g01014840

10. Install Tooling (C) on differential assembly (11). Attach a hoist and suitable lifting chains to Tooling (C).

11. Use the hoist to install differential assembly (11). The weight of the differential assembly is approximately 109 kg (240 lb).
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    Illustration 5	g01014817

    Note: Use the original shim pack or a new shim pack of the same thickness. If the original shim pack is not available, use 60 percent of a new shim pack.

12. Apply Tooling (K) to the O-ring seal before you install the O-ring seal on the pinion housing. Install two 152.4 mm (6 inch) guide bolts in the axle center housing. Install the shim pack on the pinion housing.

13. Install Tooling (B) on the pinion gear assembly. Attach a suitable lifting device to Tooling (B).

14. Use the suitable lifting device to install pinion gear assembly (10). The weight of the pinion gear assembly is approximately 66 kg (145 lb).
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    Illustration 6	g00337022

15. Install bolts (9). The torque for bolts (9) is 240 ± 40 N·m (175 ± 30 lb ft).

    Note: The thickness of the shim pack may need to be changed when you adjust the tooth contact pattern.

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    Illustration 7	g00337021

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    Illustration 8	g00337020

16. Install bearing cup (8), sleeve assembly (6), and locating pin (7) in intermediate housing (1).

17. Apply lubricant to the threads on adjusting nut (5). Install adjusting nut (5) in intermediate housing (1). Do not install bolt lock (4) and bolt (3) at this time.
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    Illustration 9	g00337019

18. Fasten a suitable lifting device to intermediate housing (1). Use the suitable lifting device to install intermediate housing (1). Install bolts (2) that hold the intermediate housing to the axle center housing.
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    Illustration 10	g00337031

19. Position the axle center housing horizontally on Tooling (A).

20. Use Tooling (F) and Tooling (G) to tighten adjusting nuts (5) and (16) to a position which maintains gear backlash and slight bearing end play.

21. Measure the torque that is required to rotate the pinion shaft. Record the measured torque. Use a Tooling (I) on the pinion shaft nut for this measurement.

22. While you are rotating the pinion shaft back and forth, tighten adjusting nut (16) to the zero backlash position. Then back off adjusting nut (16) by 20 degrees plus the increment to the nearest lock position.

23. Tighten adjusting nut (5) on the bevel gear group while you are rotating the pinion shaft. Tighten nut (5) until the overall preload rolling torque that is measured at the pinion shaft is 1.8 to 7.4 N·m (16 to 65 lb in) to the nearest lock position.
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    Illustration 11	g00315693
    Backlash Measurement for the Pinion Shaft Spline (A) Distance of the dial indicator from the centerline of the pinion.

    Note: Measure the rolling torque of the gears at the pinion shaft to ensure the correct assembly and adjustment. For new bearings, the rolling torque should be 1.8 to 7.4 N·m (16 to 65 lb in). For used bearings, the rolling torque should be 0.9 to 3.7 N·m (8 to 33 lb in).

24. Place a dial indicator tangent to the spline, as shown. Make sure that the yoke or the spline adapter is tight to the spline. Measure the backlash between bevel gear (25) and the pinion shaft. The backlash measurement must be 0.28 ± 0.13 mm (−0.011 ± 0.005 inch).

    The following chart gives examples of backlash at the pinion shaft by showing the different distances from the pinion centerline to the dial indicator.

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    Table 2

    Examples of Backlash at Pinion Shaft
    Dimension (A)	Nominal Backlash	Maximum Backlash	Minimum Backlash
    50 mm (2 inch)	0.28 mm (.011 inch)	0.40 mm (.016 inch)	0.18 mm (.007 inch)
    100 mm (4 inch)	0.55 mm (.022 inch)	0.80 mm (.032 inch)	0.35 mm (.014 inch)
    150 mm (6 inch)	0.83 mm (.033 inch)	1.20 mm (.047 inch)	0.53 mm (.021 inch)
    200 mm (8 inch)	1.10 mm (.043 inch)	1.60 mm (.063 inch)	0.70 mm (.028 inch)

25. If the backlash does not meet the specifications, loosen one adjusting nut and tighten the opposite adjusting nut by the same amount. This will maintain the bearing preload.

26. After the adjustments are made, remove any dyes or paint from the gears.

27. Install bolt lock (4) and bolt (3) in adjusting nut (5). Do not bend bolt lock (4) at this time.

28. Install bolt lock (15) and bolt (14) in adjusting nut (16). Do not bend bolt lock (15) at this time.
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    Illustration 12	g00315875

29. After the backlash adjustment and the preload adjustment have been made, the tooth contact between the pinion shaft and bevel gear (25) must be checked. Use the following procedure:

    1. Put a small amount of Prussian blue, red lead, or paint on three or four adjacent teeth of bevel gear (25).

    2. Rotate the pinion shaft for several revolutions in one direction. Then rotate the pinion shaft for several revolutions in the opposite direction. Then turn the pinion shaft in the original direction to observe the marked teeth.

    3. The correct area of tooth contact begins near the inside end of the teeth. The contact area should extend to a maximum of 50 percent of the length of the teeth. Illustration 12 is an example of the correct area of tooth contact.
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    Illustration 13	g00315877

30. If the tooth contact looks like the marks in Illustration 13, perform the following procedure:

    1. Remove some of the shims that are behind the pinion housing.

    2. Repeat Steps 24 through 25 for the backlash adjustment.
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    Illustration 14	g00315878

31. If the tooth contact looks like the marks in Illustration 14, perform the following procedure:

    1. Add shims behind the pinion housing.

    2. Repeat Steps 24 through 25 for the backlash adjustment.

       Note: Always make sure that the backlash adjustment is correct before an adjustment is made to the area of tooth contact. Several adjustments to the backlash and to the tooth contact may be necessary to achieve the correct adjustments. A change to gear backlash will also change the gear contact and vice versa.

32. After the adjustments are made, remove any dyes or paint from the gears.

33. Install bolt lock (4) and bolt (3) in adjusting nut (5).

34. Install bolt lock (15) and bolt (14) in adjusting nut (16).

35. Bend the locks.

36. Install the service brakes. Refer to Disassembly and Assembly, "Service Brakes - Remove and Install".

End By:

1. Install the rear oscillating axle. Refer to Disassembly and Assembly, "Oscillating Axle (Rear) - Remove and Install".

2. Install the front fixed axle. Refer to Disassembly and Assembly, "Fixed Axle (Front) - Remove and Install".

3. Separate the steering frame lock. Refer to Disassembly and Assembly, "Steering Frame Lock - Separate and Connect".