D250E Series II and D300E Series II Articulated Trucks Power Train Caterpillar

Assembly Procedure

1. Clean all parts and inspect all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

Show/hide table



Illustration 1	g00446903

2. Use Tool (D) and a press and install bearing (61) into housing (27) .

Show/hide table



Illustration 2	g00446443

3. Install ring seal (60) on housing (27) .

Show/hide table



Illustration 3	g00446027

4. Install ring seal (59) onto piston (58) .

Show/hide table



Illustration 4	g00445804

5. Use two 3/8" - 16 NC eyebolts (57) in order to install clutch piston (58) into housing (27) .

Show/hide table



Illustration 5	g00445723

6. Install friction disc (56) into housing (27) .

Show/hide table



Illustration 6	g00445664

7. Install backing plate (55) into housing (27) .

Show/hide table



Illustration 7	g00445444

8. Install retaining ring (54) into housing (27) .

Show/hide table



Illustration 8	g00445403

9. Install retaining ring (53) and seal ring (52) onto turbine hub (51) .

Show/hide table



Illustration 9	g00524510

10. Position turbine hub (51) onto converter turbine (37) and install sixteen bolts (50) . Tighten the bolts to a torque of 49 ± 3 N·m (36 ± 2 lb ft).

Show/hide table



Illustration 10	g00524636

11. Install converter turbine (37) into housing (27) .

Show/hide table



Illustration 11	g00524488

12. Install bearing thrust race (48) , thrust bearing (47) and bearing retainer (46) onto converter turbine (37) .

Show/hide table



Illustration 12	g00444503

13. Install freewheel cam (41) into stator (36) .

Show/hide table



Illustration 13	g00444403

14. Position thrust race (45) and install retaining ring (44) onto stator (36) .

Show/hide table



Illustration 14	g00444366

Show/hide table



Illustration 15	g00524637

15. Always use new springs (43) and rollers (42) in the one-way clutch. Install new freewheel springs (43) and freewheel rollers (42) into freewheel cam (41) . When you install the springs, position the springs with the maximum number of loops in the spring to the outside of the cam assembly.

Show/hide table



Illustration 16	g00444343

16. Install freewheel race (40) into freewheel cam (41) .

Show/hide table



Illustration 17	g00444273

17. Position thrust race (39) and install retaining ring (38) onto stator (36) .

Show/hide table



Illustration 18	g00444271

18. Install stator (36) onto converter turbine (37) .

Show/hide table



Illustration 19	g00444270

19. Install thrust bearing (35) onto stator (36) .

Show/hide table



Illustration 20	g00444269

20. Position bearing thrust race (34) and install bearing retainer (33) onto stator (36) .

Show/hide table



Illustration 21	g00444126

21. Install impeller hub (31) onto impeller (26) .

Show/hide table



Illustration 22	g00443683

22. Position pump drive gear (30) onto impeller (26) .

Show/hide table



Illustration 23	g00443647

23. Turn impeller (26) onto the other side. Install eight bolts (29) in order to install pump drive gear (30) onto impeller (26) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

Show/hide table



Illustration 24	g00443503

24. Position impeller (26) onto housing (27) and install 36 bolts (25) . Tighten bolts (25) to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

Show/hide table



Illustration 25	g00447623

Show/hide table

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

25. Heat ring carrier (23) and bearing (24) to a temperature of 149°C (300°F) and install bearing (24) and ring carrier (23) onto stator carrier (20) .

    Note: Ring carrier (23) has a through hole which forms an orifice at one end. The small orificed end must face bearing (24) .

Show/hide table



Illustration 26	g00443313

26. Install retaining ring (22) onto stator carrier (20) .

Show/hide table



Illustration 27	g00443307

27. Install two O-ring seals (21) onto stator carrier (20) .

Show/hide table



Illustration 28	g00443304

28. Install stator carrier (20) into torque converter (12) .

Show/hide table



Illustration 29	g00447804

29. Install bearing (19) onto shaft (16) .

Show/hide table



Illustration 30	g00441769

30. Install retaining ring (18) onto shaft (16) .

Show/hide table



Illustration 31	g00441763

31. Install two O-ring seals (17) onto shaft (16) .

Show/hide table



Illustration 32	g00441583

32. Install shaft (16) into torque converter (12) .

Show/hide table



Illustration 33	g00441527

33. Install seal (15) onto shaft (16) .

Show/hide table



Illustration 34	g00441450

34. Position retainer (14) and the shims and install two bolts (13) onto torque converter (12) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

Show/hide table



Illustration 35	g00508520

35. Position flange assembly (11) and install fourteen bolts (10) . Tighten bolts (10) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).

Show/hide table



Illustration 36	g00441172

36. Use Tooling (A) , a hoist and an appropriate lifting device in order to position housing (8) onto the torque converter. The housing weighs approximately 140 kg (308 lb).

Show/hide table



Illustration 37	g00447913

37. Use Tooling (B) and install lip type seal (9) in carrier (6) . Make sure that the side of the seal with the gap faces toward the torque converter.

Show/hide table



Illustration 38	g00440546

38. Position carrier (6) onto the housing and install eight bolts (5) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

Show/hide table



Illustration 39	g00440545

39. Install the seal, yoke (3) , retainer (2) and bolt (1) onto shaft (4) . Tighten bolt (1) to a torque of 120 ± 15 N·m (89 ± 11 lb ft).

End By: Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter and Retarder - Connect". The information is in this manual.