793C Off-Highway Truck/Tractor Power Train Caterpillar

Assembly Procedure

Show/hide table

Illustration 1	g00511396

1. Raise the temperature of inner bearing (99). Install inner bearing (99) and snap ring (98) on stator carrier (84).
   Show/hide table

   Illustration 2	g00511155

2. Install two seal rings (97) on stator carrier (84).
   Show/hide table

   Illustration 3	g00511398

3. Raise the temperature of ring carrier (95). Install ring carrier (95) on output shaft (91). Use a brass drift to be certain that ring carrier (95) is properly seated.
   Show/hide table

   Illustration 4	g00511399

4. Raise the temperature of ball bearing (96). Install ball bearing (96) on output shaft (91). Use a brass drift to be certain that ball bearing (96) is properly seated.
   Show/hide table

   Illustration 5	g00511400

5. Raise the temperature of ring carrier (93). Install ring carrier (93) on output shaft (91). Use a brass drift to be certain that ring carrier (93) is properly seated.
   Show/hide table

   Illustration 6	g00511152

6. Install two seal rings (92) on ring carrier (93). Install seal ring (94) (not shown) on ring carrier (95).
   Show/hide table

   Illustration 7	g00511403

   Show/hide table

   Illustration 8	g00511404

7. Position stator carrier (84) on a suitable stand. Use Tool (F) and a suitable lifting device to lower output shaft (91) into stator carrier (84). If necessary, use a soft hammer to seat the bearing against the shoulder in stator carrier (84).
   Show/hide table

   Illustration 9	g00511150

8. Install sensor rotor (89), plug (90), and the O-ring seal in distributor (86).

   Note: Before installation, apply 1U-6396 O-Ring Assembly Compound to the O-ring seals.

   Show/hide table

   Illustration 10	g00511405

9. Use Tool (D) to install lip seal (88) on distributor (86). Refer to Reuse and Salvage Guidelines, "Lip Type Seals"SEBF9247 for the proper lip seal installation procedure.

   Note: During the installation of lip seal (88), do not reuse existing lip seal (88).

   Show/hide table

   Illustration 11	g00511147

10. Install gasket (87) on stator carrier (84).
    Show/hide table

    Illustration 12	g00511146

11. Install distributor (86), 12 bolts (85), and 12 washers on stator carrier (84). Tighten bolts (85) to a torque of 50 ± 7 N·m (36.9 ± 5.2 lb ft).
    Show/hide table

    Illustration 13	g00511145

12. Turn over the assembly. The weight of the assembly is 329 kg (725.3 lb). Install freewheel race (83), split washer (82), and six bolts (81). Tighten bolts (81) to a torque of 30 ± 5 N·m (22.1 ± 3.7 lb ft).
    Show/hide table

    Illustration 14	g00511426

    Show/hide table

    Illustration 15	g00511427

13. Install O-ring seal (77) on drive flange (73). Use a suitable driver to install wear sleeve (80) into drive flange (73).
    Show/hide table

    Illustration 16	g00511428

14. Turn over drive flange (73). Drive flange (73) weighs 57 kg (125.7 lb). Install pump drive gear (79) and 12 bolts (78) on drive flange (73). Tighten bolts (78) to a torque of 50 ± 7 N·m (36.9 ± 5.2 lb ft).
    Show/hide table

    Illustration 17	g00511141

15. Use two people to install impeller (72) on drive flange (73). Impeller (72) weighs 25 kg (55.1 lb).

    Note: During the installation of impeller (72), be certain that the identification marks are aligned.

    Show/hide table

    Illustration 18	g00511139

16. Install O-ring seal (76) on impeller hub (71).
    Show/hide table

    Illustration 19	g00511138

17. Install thrust race (75) on impeller hub (71).
    Show/hide table

    Illustration 20	g00511137

18. Install impeller hub (71) and eight bolts (74) on converter turbine (72). Tighten bolts (74) to a torque of 80 ± 10 N·m (59.01 ± 7.38 lb ft).
    Show/hide table

    Illustration 21	g01014480

19. Use Tool (A) and a suitable lifting device to install impeller (72) and drive flange (73) on the output shaft. The combined weight of impeller (72) and drive flange (73) is 84 kg (185.2 lb).
    Show/hide table

    Illustration 22	g00511135

20. Install needle bearing (70) on impeller hub (71).
    Show/hide table

    Illustration 23	g00511429

21. Use Tool (D) and a suitable press to install bearing sleeve (69) into race (66). After assembly, the diameter of the bearing bore must be 127.19 ± .02 mm (5.008 ± 0.001 inch).
    Show/hide table

    Illustration 24	g00511431

22. Install retaining ring (67) in converter stator (60).
    Show/hide table

    Illustration 25	g00511432

23. Raise the temperature of converter stator (60) to a maximum temperature of 148 °C (298.4 °F) for at least twenty minutes. Install race (66) into converter stator (60). Use a set punch to set converter stator (60) in two places to retain race (66).
    Show/hide table

    Illustration 26	g00511433

24. Turn over converter stator (60). Install freewheel cam (68) in converter stator (60).
    Show/hide table

    Illustration 27	g00511435

25. Install two springs (65) and roller cage (64) in converter stator (60).
    Show/hide table

    Illustration 28	g00511127

26. Install 24 freewheel rollers (63) in roller cage (64). Use grease to hold freewheel rollers (63) in place.
    Show/hide table

    Illustration 29	g00511436

27. Use Tool (D) and a suitable press to install bearing sleeve (62) into bearing support (59). The bearing bore must be 127.19 ± .08 mm (5.008 ± 0.003 inch).
    Show/hide table

    Illustration 30	g01014478

28. Install bearing support (59), Tool (E), and five bolts (61). Tighten bolts (61) to a torque of 30 ± 5 N·m (22.1 ± 3.7 lb ft).
    Show/hide table

    Illustration 31	g01014475

29. Install converter stator (60) on the converter turbine.

30. Remove Tool (E). Install three remaining bolts (61). Tighten the bolts to the torque that was specified in Step 28.
    Show/hide table

    Illustration 32	g00511119

31. Install needle bearing (58) on bearing support (59).
    Show/hide table

    Illustration 33	g00511118

32. Install wear sleeve (55). Install seal ring (56) and plug (57) on clutch housing (46). Use a brass drift to be certain that wear sleeve (55) is properly seated.
    Show/hide table

    Illustration 34	g00511113

33. Install seal ring (50) on ring carrier (48).
    Show/hide table

    Illustration 35	g00511439

34. Install ring carrier (48) on hub (47).
    Show/hide table

    Illustration 36	g00511116

35. Lubricate seal ring (52) with a suitable lubricant. Install seal ring (52) on clutch piston (51).
    Show/hide table

    Illustration 37	g00511442

36. Install clutch piston (51) on hub (47).
    Show/hide table

    Illustration 38	g01014617

37. Use Tool (A) and a suitable lifting device to lower clutch housing (46) on clutch piston (51) and hub (47). Clutch housing (46) weighs 68 kg (149.9 lb).
    Show/hide table

    Illustration 39	g00511444

    Show/hide table

    Illustration 40	g00511446

    Show/hide table

    Illustration 41	g00511447

    Show/hide table

    NOTICE
    Pay attention to the orientation of the bearings. The bearings must be properly installed. If the bearings are improperly installed, premature failure of the bearings will occur.

38. Install bearings (53) and (54) in clutch housing (46). Use a suitable driver to be certain that bearings (53) and (54) are properly seated.
    Show/hide table

    Illustration 42	g00511448

39. Use a screwdriver to install locking ring (49) in hub (47).
    Show/hide table

    Illustration 43	g00511108

    Show/hide table

    Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation.

40. Install Tool (B) to prevent hub (47) from falling.

    Note: Tool (B) must be installed in the hub to prevent the hub and the turbine assembly from falling.

    Show/hide table

    Illustration 44	g00511453

41. Turn over clutch housing (46). Install four friction discs (48) and three clutch plates (49).

    Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to install the discs and the plates in this order. Install a friction disc last.

    Show/hide table

    Illustration 45	g00511107

42. Install pipe plug (45) in rotating housing (34).
    Show/hide table

    Illustration 46	g01014472

43. Use Tool (C) and a suitable lifting device to lower rotating housing (34) on clutch housing (46). Rotating housing (34) weighs approximately 59 kg (130.1 lb).
    Show/hide table

    Illustration 47	g00511105

44. Install 26 bolts (44) and the 26 washers. Tighten the bolts to a torque of 240 ± 25 N·m (177.01 ± 18.44 lb ft).

    Note: Initially tighten two bolts that are separated by 180 degrees. Rotate 45° ± 12° until eight bolts are tightened. Tighten all the bolts.

    Show/hide table

    Illustration 48	g00511104

45. Use two people to install turbine (41) in housing (34). Turbine (41) weighs 27 kg (59.5 lb).
    Show/hide table

    Illustration 49	g00511102

46. Install two dowels (43) in support (37).
    Show/hide table

    Illustration 50	g00511101

47. Use Tool (D) and a suitable press to install bearing sleeve (42) in support (37).
    Show/hide table

    Illustration 51	g00511100

48. Lower the temperature of support (37). Install support (37) in converter turbine (41). Install eight springs (40) in support (37).
    Show/hide table

    Illustration 52	g00511098

49. Install thrust race (39), the two washers, and two bolts (38) on support (37).

    Note: When bolts (38) are tightened, evenly compress the springs behind thrust race (39).

    Show/hide table

    Illustration 53	g00511097

50. Bolts (36) are twelve point head bolts. Install 10 bolts (36) and the ten washers into rotating housing (34). Tighten 10 bolts (36) and two bolts (38) to a torque of 80 ± 10 N·m (59.01 ± 7.38 lb ft).
    Show/hide table

    Illustration 54	g00511094

51. Use Tool (A) and a suitable lifting device to install rotating housing (34) on the torque converter. Rotating housing (34) weighs 227 kg (500.5 lb). Install the 30 washers and 30 bolts (35). Tighten the bolts to a torque of 135 ± 15 N·m (99.6 ± 11.1 lb ft).

    Note: Initially tighten two bolts that are separated by 180 degrees. Rotate 45° ± 12° until eight bolts are tightened. Tighten all the bolts.

    Note: Be certain that the identification marks are aligned.

    Show/hide table

    Illustration 55	g00511455

52. Remove Tool (B) from the hub.
    Show/hide table

    Illustration 56	g00511089

53. Install the spring washer and plate retainer (33). Install three bolts (32). Tighten bolts (32) to a torque of 240 ± 25 N·m (177.01 ± 18.44 lb ft).
    Show/hide table

    Illustration 57	g00511456

54. Install flywheel pilot (31), Tool (A), the ten washers, and ten bolts (30). Tighten bolts (30) to a torque of 120 ± 15 N·m (88.5 ± 11.1 lb ft).

55. Remove the torque converter from the stand.

56. Remove Tool (A). Install the two remaining bolts and washers. Tighten the two bolts to the torque that was specified in Step 54.
    Show/hide table

    Illustration 58	g00511065

57. Install yoke (29) on the torque converter.
    Show/hide table

    Illustration 59	g00511064

58. Install O-ring seal (28) on the torque converter.
    Show/hide table

    Illustration 60	g00511063

59. Install retainer (27) and bolt (26) on the torque converter.
    Show/hide table

    Illustration 61	g00511062

60. Install two O-ring seals (25) on the torque converter.
    Show/hide table

    Illustration 62	g00511060

61. Install dowel (24) in torque converter housing (3).
    Show/hide table

    Illustration 63	g00511059

62. Install two plugs (23) and two O-ring seals on torque converter housing (3).
    Show/hide table

    Illustration 64	g00511057

63. Install orifice plug (22) in torque converter housing (3).
    Show/hide table

    Illustration 65	g00511056

64. Install two plugs (21) and two O-ring seals on torque converter housing (3).
    Show/hide table

    Illustration 66	g00511053

65. Install gasket (18), two oil level sight gauges (19), and two grommets (20) on torque converter housing (3).
    Show/hide table

    Illustration 67	g00511052

66. Install plate (17), eight washers, and eight bolts (16) on torque converter housing (3).
    Show/hide table

    Illustration 68	g00511051

67. Install support (15), four washers, and four bolts (14) on torque converter housing (3).
    Show/hide table

    Illustration 69	g00511457

68. Install mud flap (13), eight nuts (12), eight washers, and eight bolts (11).
    Show/hide table

    Illustration 70	g00511047

    Show/hide table

    Illustration 71	g00511046

69. Use Tool (A) and a suitable lifting device to install torque converter housing (3) on the torque converter. Torque converter housing (3) weighs 329 kg (725.3 lb).

70. Install 17 bolts (10) on the torque converter.
    Show/hide table

    Illustration 72	g00511044

71. Install O-ring seal (9) on baffle (8).
    Show/hide table

    Illustration 73	g00511043

72. Install baffle (8), six washers, and six bolts (7) on torque converter housing (3).
    Show/hide table

    Illustration 74	g00511041

73. Install O-ring seal (6) on cover (5).
    Show/hide table

    Illustration 75	g00511038

74. Install the screen. Install cover (5), four washers, and four bolts (4) on torque converter housing (3).

75. Install cover gasket (2), six washers, and six bolts (1) on torque converter housing (3).

End By:

1. If necessary, install the two sensors for the Wiggins Service Center.

2. Install the torque converter screen. Refer to Disassembly and Assembly, "Screen (Torque Converter) - Install".

3. Install the lockup clutch and synchronizing valve of the torque converter. Refer to Disassembly and Assembly, "Lockup Clutch and Synchronizing Valve - Remove and Install".

4. Install the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Relief Valve (Torque Converter Outlet) - Remove and Install".

5. Install the torque converter inlet relief valve. Refer to Disassembly and Assembly, "Relief Valve (Torque Converter Inlet) - Remove and Install".

6. Install the transmission and torque converter pump. Refer to Disassembly and Assembly, "Gear Pump (Torque Converter and Transmission) - Install".

7. Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Install".