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

Output Transfer Gears - Assemble

Usage:

Assembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	6V-2156	Link Bracket	2
C	5P-5197	Retaining Ring Pliers	1
D	1P-0510	Driver Group	1
E	5P-4758	Retaining Ring Pliers	1

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Illustration 1	g00518147

Lower the temperature of bearing races (30) and install bearing races (30) in the output transfer gear housing.
Note: Make sure that the bearing races are correctly seated.

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Illustration 2	g00518146

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Illustration 3	g00518144

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Illustration 4	g00518427

Note: Steps 2 through 3 should be done simultaneously.

Heat bearing (27) , bearing (29) and idler gear (28) to a temperature of 135 °C (275 °F). Install bearing (29) and idler gear (28) in the output transfer gear housing.

Note: Make sure that the counterbore surface of the gear is facing upward.

Lower the temperature of the idler gear shaft (26) in order to achieve a 100 °C (212 °F) temperature differential between idler gear (28) and idler gear shaft (26) . Install the idler gear shaft (26) in the housing while bearing (29) and idler gear (28) are still hot.

Immediately install bearing (27) on the idler gear shaft (26) .

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Illustration 5	g00521506

Heat both bearings (25) for the input gear to a temperature of 135 °C (275 °F). Install both bearings (25) on the input gear (24) .

Attach input gear (24) to a suitable lifting device and place input gear (24) in the output transfer gear housing.

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Illustration 6	g00518127

Install piston (20) and reaction plate (21) in the brake housing.

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Illustration 7	g00518486

Use Tooling (A) in order to attach the brake housing to a suitable lifting device. Place the brake housing on the output transfer drive and install the six bolts.
Note: See Specifications, SENR8636, "Output Transfer Drive Bearing Adjustment Procedure and Brake Check" .

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Illustration 8	g00518489

Install nine discs and eight friction discs (19) . Start by installing a disc and then install a friction disc. Install plate (18) and O-ring (17) .

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Illustration 9	g00518491

Notice the orientation of the four springs (16) . Install four springs (16) on the cover plate. Use Tooling (C) in order to install retainer ring (15) .

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Illustration 10	g00518492

Install cover plate (14) on the brake housing. Install the six bolts. Tighten two opposite bolts at a time in order to evenly compress the springs.

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Illustration 11	g00518495

Install seal (31) in the flange of the output yoke (5) . Install the seal with the lip of the seal toward the roller bearing.

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Illustration 12	g00518496

Install roller bearing (10) . Use pliers (E) in order to install retainer ring (9) .

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Illustration 13	g00518022

Install thrust washer (7) and O-ring (8) on flange assembly (5) .

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Illustration 14	g00518498

Place the output yoke flange assembly in a press. Install yoke (6) on flange assembly (5) with the press and tool (D) .

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Illustration 15	g00517848

Use pliers (C) in order to install retainer ring (4) on the output yoke flange assembly.

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Illustration 16	g00518502

Install output yoke (5) with six bolts (3) .

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Illustration 17	g00517823

Flip the output transfer drive. Attach lifting links (A) and a hoist to the yoke for the interaxle differential. Install the interaxle differential assembly in the output transfer gear housing. Install bolts (2) .

Install the yoke and the carrier assembly to the output transfer gear housing without the O-ring seals or the shims. Install the six bolts. Use a feeler gauge in order to measure the distance between the yoke assembly and the carrier housing. Document the distance.

Remove the yoke assembly from the housing.

Install the thickness of shims that was measured in step 19 .

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Illustration 18	g00517791

Install bolt (1) in the output yoke.

End By:

Connect the output transfer gears to the transmission. See Disassembly and Assembly, "Transmission and Transfer Gears - Connect" .
Install the housing for the transmission speed sensor. See Disassembly and Assembly, "Speed Sensor (Transmission) - Remove and Install" .