793C Off-Highway Truck/Tractor Power Train Caterpillar

Assembly Procedure

Note: Inspect the O-ring seals. Replace any O-ring seals that are worn or damaged. Lubricate the O-ring seals with the fluid that is being sealed.

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Illustration 1	g00512452

1. Lower bearing cup (38) to a temperature of −50 °C (−58.0 °F). Use Tooling (E) (not shown) to install roller bearing cup (38) in transfer case (2).
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   Illustration 2	g00512450

2. Raise bearing cone (37) to a temperature of 149 °C (300.2 °F). Use a suitable driver to install roller bearing cone (37) on transfer gear (35).
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   Illustration 3	g00512448

3. Turn over gear assembly (35). Raise bearing cone (36) to a temperature of 149 °C (300.2 °F). Use a suitable driver to install roller bearing cone (36) on transfer gear (35).
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   Illustration 4	g00512446

4. Use a suitable lifting device to install transfer gear (35) in transfer case (2). The weight of transfer gear (35) is approximately 41 kg (90.4 lb).
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   Illustration 5	g00512444

5. Install the O-ring seal and plug (34) on bearing cage (26).
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   Illustration 6	g00512519

6. Raise bearing cone (33) to a temperature of 149 °C (300.2 °F). Use a suitable driver to install bearing cone (33) on carrier (30).

7. Install orifice plug (32) in carrier (30).
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   Illustration 7	g00512440

8. Lower carrier (30) and bearing cup (31) to a temperature of −50 °C (−58.0 °F). Use a suitable driver to install carrier (30) and bearing cup (31) in bearing cage (26).
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   Illustration 8	g00512439

9. Install bolts (28) and seal rings (29) on carrier (30).
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   Illustration 9	g01014379

10. Use Tooling (A) and a suitable lifting device to install bearing cage (26) on transfer case (2). The weight of bearing cage (26) is approximately 34 kg (74.9 lb).
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    Illustration 10	g00512434

    Note: Do not install shims (27) (not shown) at this time.

11. Install brass washer (25), the washers, and bolts (24) on transfer case (2). Tighten bolts (24) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 11	g00512521

12. Rotate transfer gear (35) (not shown) by three revolutions in each direction.

13. Use Tooling (B) and Tooling (C) to measure the end play.

    Note: Tooling (B) is a factory tool.

14. Assemble a shim. The minimum thickness of shim (27) will equal the end play minus 0.18 mm (0.007 inch). The maximum thickness of the shim will equal the end play minus 0.10 mm (0.004 inch).
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    Illustration 12	g00512434

15. Remove bolts (24), the washers, brass washer (25), and the bearing cage from transfer case (2).
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    Illustration 13	g00512438

16. Install shim pack (27) on transfer case (2).
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    Illustration 14	g00512434

17. Use brass washer (25), the washers, and bolts (24) to install the bearing cage on transfer case (2). Tighten bolts (24) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 15	g00512521

18. Rotate transfer gear (35) (not shown) by three revolutions in each direction.

19. Use Tooling (B) and Tooling (C) to measure the end play. If the measurement of the end play is within 0.10 mm to 0.18 mm (0.004 inch to 0.007 inch), continue the assembly procedure. If the end play is not within the specified range, repeat Steps 14 to 18.
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    Illustration 16	g00512432

20. Install the O-ring seals, adapter (23), and plug (22) on transfer case (2).
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    Illustration 17	g00512430

21. Install the O-ring seal and nipple (20). Install ball (21) in transfer case (2).
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    Illustration 18	g00512428

22. Install flared connector (19) and tube (18) in transfer case (2).
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    Illustration 19	g00512427

23. Install tube assembly (14) and the flared elbow. Lower the temperature of bearing cup (15) to −50 °C (−58.0 °F). Use a suitable driver to install bearing cup (15). Install orifice plug (16) and ball (17) in transfer case (2).
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    Illustration 20	g00512522

24. Raise the temperature of bearing cones (12) and (13) to 149 °C (300.2 °F). Install bearing cones (12) and (13) on transfer gear (11).
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    Illustration 21	g00512523

25. Use Tooling (D) and a suitable lifting device to install transfer gear (11) in transfer case (2). The weight of transfer gear (11) is approximately 66 kg (145.5 lb).
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    Illustration 22	g00512418

26. Lower the temperature of bearing cup (10) to −50 °C (−58.0 °F). Install bearing cup (10) in bearing cage (4).
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    Illustration 23	g00512525

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    Illustration 24	g00512546

27. Use Tooling (E) to install lip seal (9) in bearing cage (4). Refer to Reuse and Salvage Guidelines, "Lip Type Seals"SEBF9247 for the proper lip seal installation procedure.
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    Illustration 25	g00512414

28. Install O-ring seals (6) and (7). Install ball (8) in bearing cage (4).
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    Illustration 26	g01014384

29. Use Tooling (A) and a suitable lifting device to install bearing cage (4) on transfer case (2). The weight of bearing cage (4) is approximately 25 kg (55.1 lb).
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    Illustration 27	g00512406

    Note: Do not install shims (5) (not shown) at this time.

30. Install the washers and bolts (3) on transfer case (2). Tighten bolts (3) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 28	g00512548

31. Rotate transfer gear (11) (not shown) by three revolutions in each direction.

32. Use Tooling (B) and Tooling (C) to measure the end play.

    Note: Tooling (B) is a factory tool.

33. Assemble a shim (not shown). The minimum thickness of shim (5) is equal to the end play minus 0.18 mm (0.007 inch). The maximum thickness of shim (5) is equal to the end play minus 0.10 mm (0.004 inch).
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    Illustration 29	g00512406

34. Remove bolts (3), the washers, and the bearing cage from transfer case (2).
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    Illustration 30	g00512412

35. Remove shim pack (5) from transfer case (2).
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    Illustration 31	g00512406

36. Install the bearing cage, 16 bolts (3) and the washers on transfer case (2). Tighten bolts (3) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 32	g00512548

37. Rotate transfer gear (11) by three revolutions in each direction.

38. Use Tooling (B) and Tooling (C) to measure the end play. If the end play is within 0.10 mm to 0.18 mm (0.004 inch to 0.007 inch), continue the assembly procedure. If the end play is not within the specified range, repeat Steps 33 to 37.

39. Install dust cap (1) on transfer case (2).

End By:

1. Assemble the transmission. Refer to Disassembly and Assembly, "Transmission Planetary - Assemble".

2. Install the transmission and transfer gears. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Install".