980G Wheel Loader Power Train Caterpillar

Output Transfer Gears - Assemble

Usage:

980G 2KR

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0520	Driver Group	1
C	138-7575	Link Bracket	2
E	138-8436	Liquid Gasket	1
F	6V-6640	Sealant	1
G		1/2 in - 13 X 2 in Guide Bolts	2
H	1P-0510	Driver Gp	1

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 which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

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Illustration 1	g01088878

Use the proper equipment to handle bearing cup (52) and roller bearing cup (53). Lower the temperature of bearing cup (53) and roller bearing cup (52) and install bearing cup (53) and roller bearing cup (52) in the transfer case.
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Illustration 2 g01088877
Use the proper equipment to handle roller bearing cones (51). Heat two roller bearing cones (51) to a maximum temperature of 135°C (275°F). Install roller bearing cone (51) on each side of input gear (48).
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Illustration 3 g01088875
Use the proper equipment to handle bearing cones (50). Heat bearing cones (50) to a maximum temperature of 135°C (275°F) and install bearing cone (50) on each side of idler gear (47).
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Illustration 4 g01088867

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Illustration 5 g01088903
Use two people to install input gear (47) in the transfer case. The weight of input gear (47) is approximately 34 kg (75 lb).
Use two people to install idler gear (48) in the transfer case. The weight of idler gear (48) is approximately 41 kg (90 lb).
Apply Tooling (E) on the threads of speed sensor assembly (49). Use a feeler gauge to position speed sensor assembly (49). The correct distance is 0.71 mm (0.028 inch) away from the input gear tooth. Tighten the nut that retains the speed sensor to a torque of 25 ± 5 N·m (18 ± 4 lb ft).
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Illustration 6 g01022889
Apply Tooling (F) to the machined surface of the transfer case. Install Tooling (B) and a suitable lifting device to cover (45). The weight of cover (45) is 44 kg (97 lb). Carefully lower cover (45) to the transfer case.
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Illustration 7 g01088913
Use Tooling (A) to drive two dowels (46) through cover (45) and in the transfer case, as shown.
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Illustration 8 g00506802
Install bolts (44) and the washers to cover (45).
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Illustration 9 g00506795
Use the proper equipment to handle roller bearing cup (35). Lower the temperature of roller bearing cup (35). Install roller bearing cup (35) in input bearing cage (32).
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Illustration 10 g01088919
Install Tooling (G) in cover (45), as shown.
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Illustration 11 g00508384
Install bolts (29) that are used to hold the cover.
Install input bearing cage (32). DO NOT add the shim pack at this time. Make sure that the input bearing cage does not bind with the cover.
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Illustration 12 g00506793
Install two bolts (33) and the washers on input bearing cage (32). Bolts (33) must be separated by 180 degrees. Tighten bolts (33) finger tight until the input bearing cage makes contact with the cover.
Tighten bolts (33) to a torque of 2.25 N·m (20 lb in).
Rotate the input gear for at least three revolutions in order to seat the bearings.
Tighten bolts (33) to a torque of 4.5 N·m (40 lb in).
Rotate the input gear for at least three revolutions in order to seat the bearings.
Tighten bolts (33) again to a torque of 4.5 N·m (40 lb in).
Use a feeler gauge to measure the gap between input bearing cage (32) and cover (45). Take the measurement next to each bolt (33) at the edge of input bearing cage (32).
Average the two measurements from step 20. Add 0.18 mm (0.007 inch) to the average. This result is the required thickness of the shims.
Note: The top input gear must have an end play of .08 ± 0.03 mm (0.003 ± 0.001 inch).
Remove bolts (33) and input bearing cage (32).
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Illustration 13 g00506794
Install the required number of shims (34) on the cover.
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Illustration 14 g01088924

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Illustration 15 g00506793
Install input bearing cage (32).
Remove Tooling (G).
Install bolts (33) and the washers. Tighten bolts (33) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
Remove bolts (29).
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Illustration 16 g00506801
Use the proper equipment to handle bearing cup (42). Lower the temperature of bearing cup (42). Install bearing cup (42) and O-ring seal (43) to idler bearing cage (39).
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Illustration 17 g01088931
Install Tooling (G) in cover (45), as shown.
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Illustration 18 g00508511
Install idler bearing cage (39). DO NOT add the shim pack at this time. Make sure that the idler bearing cage does not bind with the cover.
Install bolts (40) and the washers on idler bearing cage (39). Bolts (40) must be separated by 180 degrees. Tighten bolts (40) finger tight until the idler bearing cage makes contact with the cover.
Tighten bolts (40) to a torque of 2.25 N·m (20 lb in).
Rotate the idler gear for at least three revolutions in order to seat the bearings.
Tighten bolts (40) to a torque of 4.5 N·m (40 lb in).
Rotate the idler gear for at least three revolutions in order to seat the bearings.
Tighten bolts (40) again to a torque of 4.5 N·m (40 lb in).
Use a tapered feeler gauge to measure the gap between idler bearing cage (39) and cover (45). Take the measure next to each bolt (40) at the edge of idler bearing cage (39).
Average the two measurements from step 37. Add 0.18 mm (0.007 inch) to the average. This result is the required thickness of the shims.
Note: The center idler gear must have an end play of .08 ± 0.03 mm (0.003 ± 0.001 inch).
Note: If the transfer case has been modified to allow the installation of the larger 124-0503 Special Tapered Cone and the 124-0504 Tapered Cup, then adjust the center Idler gear to an end play of −.05 ± 0.03 mm (0.002 ± 0.001 inch).
Remove bolts (40) and idler bearing cage (39).
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Illustration 19 g01112454

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Illustration 20 g00506797
Install the required number of shims (41) on the cover.
Install idler bearing cage (39).
Remove Tooling (G).
Install bolts (40) and the washers. Tighten bolts (40) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
Install O-ring seal (38) in idler bearing cage (39).
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Illustration 21 g00506796
Install cover (37) on idler bearing cage (39).
Install nuts (36) and the washers.
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Illustration 22 g00506792
Install cover (30) with O-ring seal (31) (not shown) over the input bearing cage.
Install bolts (29) and the washers.
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Illustration 23 g00508554
Use the proper equipment to handle bearing cup (27). Lower the temperature of bearing cup (27) and install bearing cup (27) in bearing cage (14).
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Illustration 24 g00508555
Install two bearing cones (26) in bearing cage (14).
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Illustration 25 g00508557
Use the proper equipment to handle bearing cup (27). Lower the temperature of bearing cup (27) and install bearing cup (27) in bearing cage (14).
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Illustration 26 g00506788
Install retainer (24) on bearing cage (14).
Install bolts (23) and the washers. Tighten bolts (23) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
Install O-ring seal (25) in the groove of bearing cage (14).
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Illustration 27 g00508586
Turn bearing cage (14) to the opposite side, as shown. Apply Tooling (E) in the seal bore of bearing cage (14). DO NOT put the liquid gasket on the seal case. Allow the liquid gasket to dry.
Use Tooling (A) to install lip seal (28) in bearing cage (14). Make sure that the sealing lip is facing toward the inside of bearing cage (14). Install the seal until the seal contacts the counterbore.
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Illustration 28 g00508590
Use the proper equipment to handle bearing (22). Raise the temperature of bearing (22) to a maximum temperature of 135°C (275°F). Install bearing (22) on transfer shaft (12).
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Illustration 29 g00508597
Place transfer shaft (12) on a suitable block (not shown). Support transfer shaft (12) with two plates in a suitable press, as shown.
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Illustration 30 g00508605
Use two people to lower output gear (20) on transfer shaft (12). The weight of output gear (20) is approximately 26 kg (57 lb).
Install spacer (21) on transfer shaft (12).
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Illustration 31 g00508608
Use Tooling (A) and a suitable press to install bearing cage (14) on transfer shaft (12). The weight of bearing cage (14) is approximately 33 kg (73 lb).
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Illustration 32 g00506781
Install yoke assembly (16) and O-ring seal (19) to transfer shaft (12).
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Illustration 33 g00506780
Install retainer (18) and bolt (17). Tighten bolt (17) to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
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Illustration 34 g00508738
Attach a suitable lifting device to yoke assembly (16). The weight of bearing cage (14) and yoke assembly (16) as a unit is approximately 107 kg (235 lb). Carefully install yoke assembly (16) and bearing cage (14) in the transfer case.
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Illustration 35 g00506776
Install bolts (13) and the washers to bearing cage (14).
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Illustration 36 g00506775
Turn the transfer case to the opposite side. The weight of the output transfer gear group is approximately 525 kg (1160 lb).
Install spacer (11) on transfer shaft (12).
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Illustration 37 g00508830
Use the proper equipment to handle outer bearing race (9). Lower the temperature of outer bearing race (9). Install outer bearing race (9) in bearing cage (6).
Install O-ring seal (10) in the groove of bearing cage (6).
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Illustration 38 g00508831
Turn bearing cage (6) to the opposite side, as shown. Apply Tooling (F) in the seal bore of bearing cage (6). DO NOT put the liquid gasket on the seal case. Allow the liquid gasket to dry.
Use Tooling (A) to install lip seal (8) in bearing cage (6). Make sure that the sealing lip is facing toward the inside of bearing cage (6). Install lip seal (8) until the lip seal contacts the counterbore.
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Illustration 39 g00506768
Install bearing cage (6) on the transfer case.
Install bolts (5) and the washers. Tighten bolts (5) to a torque of 55 ± 10 N·m (40 ± 7 lb ft).
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Illustration 40 g00506766
Install yoke (4).
.
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Illustration 41 g00506765
Install O-ring seal (3).
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Illustration 42 g00506763
Install retainer (2) and bolt (1). Tighten bolt (1) to a torque of 475 ± 60 N·m (350 ± 44 lb ft).
Note: Yoke (4) must be in line with yoke assembly (16).

End By:

Connect the output transfer gears to the transmission planetary group. Refer to Disassembly and Assembly, "Output Transfer Gears to Transmission, Torque Converter - Connect" for the machine that is being serviced.