793C Off-Highway Truck/Tractor Power Train Caterpillar

Assembly Procedure

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Illustration 1	g00513500

1. Install output shaft (251) in transfer gear case (242). Use a screwdriver to install retaining ring (250) in transfer gear case (242).
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   Illustration 2	g00513499

2. Install O-ring seals (247) and (248) on bearing support housing (244). Install ball (249) on bearing support housing (244).
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   Illustration 3	g00513498

3. Use Tool (N) to install retaining ring (246) on center shaft (245).
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   Illustration 4	g00513496

4. Use a pair of pliers to squeeze retaining ring (246). Install bearing support housing (244) on center shaft (245).
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   Illustration 5	g00513494

5. Install bearing support housing (244) on transfer gear case (242). Install eight bolts (243) and eight washers. Tighten bolts (243) to a torque of 410 ± 50 N·m (302.4 ± 36.9 lb ft).

6. Turn over the transfer gear case.
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   Illustration 6	g00513492

7. Install two O-ring seal (241) on tube (240).
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   Illustration 7	g06197555

8. Use Tooling (Q) to install tube (240), two bolts (239), and two washers on the bearing cage.
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   Illustration 8	g00513489

9. Install seal (237) and race (238) on clutch housing (221).
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   Illustration 9	g00514408

10. Use Tool (M) to install roller bearing race (236).
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    Illustration 10	g00513487

11. Install metal seal ring (234) on cage (233). Install six O-ring seal (235) on cage (233).
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    Illustration 11	g01014155

12. Use Tool (L) and a suitable lifting device to lower clutch housing (221) on cage (233). Use a soft hammer to seat roller bearing race (236) in clutch housing (221). Clutch housing (221) weighs approximately 63 kg (138.9 lb).
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    Illustration 12	g00513464

13. Install seal ring (232) on clutch piston (230).
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    Illustration 13	g00513462

14. Install seal (231) on balance piston (227).
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    Illustration 14	g00514413

15. Install clutch piston (230) on clutch housing (221). Install 18 springs (229) on clutch piston (230).
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    Illustration 15	g00513458

16. Install balance piston (227). Install ten bolts (228) and ten washers on clutch housing (221).
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    Illustration 16	g01013926

17. Use Tool (L) and a suitable lifting device to install clutch housing (221). Clutch housing (221) weighs 73 kg (160.9 lb).
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    Illustration 17	g00513455

18. Install ten plugs (224) on ring gear (223).
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    Illustration 18	g00514415

19. Install ring gear (223) and two dowels (201) as guides.
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    Illustration 19	g00514416

    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.

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    Illustration 20	g00514417

    Note: Note the position of the oil grooves at point (Y) during the installation of the friction discs. During the installation of each friction disc, alternate the position of the oil grooves between points (Y) and (Z).

20. Install five friction discs (225) and four clutch plates (226) in clutch housing (221).
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    Illustration 21	g00513450

21. Install two dowels on plate (222).
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    Illustration 22	g00514418

22. Use two people to install plate (222) on clutch housing (221). Plate (222) weighs 18 kg (39.7 lb).
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    Illustration 23	g00514419

23. Use Tool (N) to install retaining ring (219) on the center shaft.
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    Illustration 24	g00514420

24. Use a pair of pliers to squeeze retaining ring (219). Install sun gear (220).
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    Illustration 25	g00513445

25. Install dowel (218) on shaft (207).
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    Illustration 26	g00513444

26. Install sleeve bearing (217) in shaft (207).
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    Illustration 27	g00514421

27. Use Tool (M) to install bearing race (216) in carrier (208).
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    Illustration 28	g00513439

28. Position carrier (208) on shaft (207). Carrier (208) weighs 23 kg (50.7 lb).

29. Use a screwdriver to install retaining ring (215) in carrier (208).
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    Illustration 29	g00513438

30. Install plug (214) in shaft (210). Repeat this procedure for the three remaining shafts.
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    Illustration 30	g00513437

31. Install two thrust discs (211), gear (212), and two roller bearings (213) in the carrier. Install shaft (210) in the carrier. Repeat this procedure for the three remaining shafts.
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    Illustration 31	g00514422

32. Use a hammer to install spring pin (209) in carrier (208). Repeat this procedure for the three remaining shafts.
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    Illustration 32	g00513434

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    Illustration 33	g00514423

33. Use Tool (P) and a suitable lifting device to install shaft (207) and carrier (208) as a unit. The combined weight of shaft (207) and carrier (208) is 79 kg (174.2 lb).
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    Illustration 34	g00514424

34. Install coupling (206), four locking plates (205), and eight locking bolts (204) on the clutch housing.
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    Illustration 35	g00514425

35. Install two dowels (201) as guides.

36. Install five friction discs (202) and four clutch plates (203) on the clutch housing.

    Note: Refer to Step 18 for the orientation of the friction disc and the clutch plate.

37. Install four remaining dowels (201) on the clutch housing.
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    Illustration 36	g01013923

38. Use Tool (L) and a suitable lifting device to install housing (200). Housing (200) weighs 34 kg (74.9 lb).
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    Illustration 37	g00513429

39. Install O-ring seal (199) on tube (194).
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    Illustration 38	g00513427

40. Install O-ring seal (197) and spring pin (198) on plug (195).
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    Illustration 39	g00513428

41. Install tube (194) through the bottom of the transfer case.
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    Illustration 40	g00513426

42. Install plug (195), the flange, and four bolts (196) to hold the tube in the proper position in the transfer case.
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    Illustration 41	g00513425

43. Install O-ring seal (193) on tube (194).
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    Illustration 42	g00513423

44. Install two balls (191) and two dowels (192) on manifold (161).
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    Illustration 43	g00513421

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    Illustration 44	g00513420

45. Install spring (188), washer (189), and valve (190) on body (187) of the lubrication relief valve.

46. Install cap (185) and O-ring seal (186) on body (187) of the lubrication relief valve.
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    Illustration 45	g00513419

47. Install lubrication relief valve (183). Tighten the lubrication relief valve to a torque of 41 ± 7 N·m (30.2 ± 5.2 lb ft). Install two plugs (184) and two O-ring seals on manifold (161).
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    Illustration 46	g00513418

48. Install two dowels (182) on ring carrier (174).
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    Illustration 47	g00513416

49. Use two lifting straps and a suitable lifting device to lower manifold (161) on ring carrier (174). Install seven bolts (181) to hold manifold (161) to ring carrier (174). Manifold (161) weighs 59 kg (130.1 lb).
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    Illustration 48	g00513415

50. Install two seal rings (178) on ring carrier (174). Install seal adapter (180) and seven bolts (179) on manifold (161).
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    Illustration 49	g00514426

51. Use Tool (M) to install ball bearing (176) in clutch (170).
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    Illustration 50	g00514427

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    Illustration 51	g00514428

52. Mark the location of dowel (182) on the top of carrier (174). Mark the location of notch (W) on bearing (176).
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    Illustration 52	g00513409

53. Turn over clutch housing (170). Install metal seal ring (177).
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    Illustration 53	g01013921

54. Use Tool (F) and a suitable lifting device to install clutch housing (170) and ball bearing (176) on ring carrier (174). The clutch housing weighs approximately 39 kg (85.9 lb).

55. Install seal ring (175) on clutch housing (170).
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    Illustration 54	g00513406

56. Use a screwdriver to install retaining ring (173) on ring carrier (174).
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    Illustration 55	g00513404

57. Install seal ring (172) on clutch piston (169).
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    Illustration 56	g00513398

58. Install clutch piston (169) in clutch housing (170). Install seal ring (171) and 18 springs (168) in clutch piston (169).
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    Illustration 57	g00513397

59. Use a suitable press to install bearing sleeve (167). Install seal ring (166) on piston (164).
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    Illustration 58	g00513396

60. Install piston (164), four washers, and four bolts (165).

    Note: When the bolts are tightened, tighten the bolts evenly to avoid damage to the seal ring.

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    Illustration 59	g00513086

61. Install seal (162) and three seal rings (163) on manifold (161).
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    Illustration 60	g01013920

62. Use Tool (H) and a suitable lifting device to install manifold (161) and the clutch as a unit. The combined weight of manifold (161) and the clutch is 125 kg (275.6 lb).
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    Illustration 61	g00513082

63. Install two bolts (160) and two washers to hold the tube in the proper position on manifold (161).
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    Illustration 62	g00513081

64. Install 16 bolts (159) and 16 washers. Tighten bolts (159) to a torque of 115 ± 7 N·m (84.8 ± 5.2 lb ft).
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    Illustration 63	g00513079

65. Install seal ring (158) on clutch piston (153).
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    Illustration 64	g00513076

66. Install 18 springs (157) on clutch piston (153).
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    Illustration 65	g00513075

67. Install seal ring (156) on balance piston (151).
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    Illustration 66	g00513073

68. Install balance piston (151) on clutch piston (153).
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    Illustration 67	g00514429

69. Use Tool (M) to install the ball bearing in clutch housing (130).
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    Illustration 68	g00513067

70. Install two dowels (155) on clutch housing (130). Use a screwdriver to install retaining ring (154) on clutch housing (130).
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    Illustration 69	g00514430

71. Align clutch piston (153) on clutch housing (130) at point (V) for installation purposes.

72. Install clutch piston (153) on clutch housing (130).

73. Install nine bolts (152) and nine washers.

    Note: Tighten bolts (152) evenly to avoid damage to the seal ring.

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    Illustration 70	g01013919

74. Use Tool (A) and a suitable lifting device to install clutch housing (130). Clutch housing (130) weighs 163 kg (359.4 lb).

    Note: Be certain that the identification marks are aligned with the dowel for installation.

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    Illustration 71	g00513038

75. Install retaining ring (149) in manifold (150).
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    Illustration 72	g00513036

76. Use Tool (N) to install retaining ring (148) on the shaft.
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    Illustration 73	g00513034

77. Install two seal rings (147) on sun gear (145).
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    Illustration 74	g00513032

78. Install retaining ring (146) on sun gear (145). Install sun gear (145) in hub (144).
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    Illustration 75	g01013918

79. Use Tool (F) and a suitable lifting device to install sun gear (145) and hub (144) on the transmission. The combined weight of sun gear (145) and hub (144) is 25 kg (55.1 lb).
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    Illustration 76	g00514431

80. Install two dowels (141) as guides.
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    Illustration 77	g00513026

81. Install five friction discs (142) and four clutch plates (143) on clutch housing (130).

    Note: Refer to Step 18 for the orientation of the friction discs and the clutch plates.

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    Illustration 78	g00513025

82. Install four remaining dowels (141) in clutch housing (130).
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    Illustration 79	g00513024

83. Install plug (140) on shaft (136). Repeat this procedure for the four remaining shafts.
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    Illustration 80	g00514432

84. Install two thrust discs (137), two roller bearings (139), and gear (138) in planetary carrier (128). Install shaft (136) in planetary carrier (128). Repeat this procedure for the four remaining assemblies.
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    Illustration 81	g00514435

85. Install spring pin (135) in shaft (136). Repeat this procedure for the four remaining shafts.
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    Illustration 82	g00514436

86. Use Tool (M) to install ball bearing (134) in planetary carrier (128).
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    Illustration 83	g00514437

87. Install retaining ring (131) in planetary carrier (128).
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    Illustration 84	g00514438

88. Lower the temperature of bearing retainer (133). Use Tool (M) to install bearing retainer (133) in planetary carrier (128).
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    Illustration 85	g00514439

89. Install O-ring seal (132) on bearing retainer (133).
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    Illustration 86	g01013917

90. Use Tool (F) and a suitable lifting device to install planetary carrier (128). Install 16 bolts (129) in clutch housing (130). Planetary carrier (128) weighs 57 kg (125.7 lb).
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    Illustration 87	g00513012

91. Install seal rings (126) and (127) on clutch piston (123).
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    Illustration 88	g01013916

92. Install four dowels (124) and two balls (125) on clutch housing (118).
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    Illustration 89	g01014180

93. Install clutch piston (123) and ring gear (122) on clutch housing (118).
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    Illustration 90	g00513004

94. Use Tool (L) and a suitable lifting device to install clutch housing (118) and ring gear (122) as a unit. The combined weight of clutch housing (118) and ring gear (122) is 125 kg (275.6 lb).
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    Illustration 91	g00513003

95. Install 16 bolts (121) and 16 washers on the transmission.
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    Illustration 92	g00514441

96. Install two dowels (117) as a guide.
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    Illustration 93	g00513001

97. Install three friction discs (119) and two clutch plates (120) on clutch housing (118).

    Note: Refer to Step 18 for the orientation of the friction discs and the clutch plates.

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    Illustration 94	g00513000

98. Install four remaining dowels (117) on clutch housing (118).
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    Illustration 95	g00512999

99. Install seal rings (115) and (116) on clutch piston (111).
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    Illustration 96	g00512998

100. Install two bolt dampers (112), 17 bolt dampers (113), and two balls (114) on clutch housing (109).
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     Illustration 97	g00514445

101. Install clutch piston (111) on clutch housing (109). Use two people to install ring gear (108) on clutch housing (109). Ring gear (108) weighs 43 kg (94.8 lb).
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     Illustration 98	g00512993

102. Install 12 springs (110) on the transmission.
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     Illustration 99	g01013904

103. Use Tool (A) and a suitable lifting device to install clutch housing (109) and ring gear (108) as a unit. The combined weight of clutch housing (109) and ring gear (108) is 114 kg (251.3 lb).
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     Illustration 100	g00512983

104. Install four lock plates (107) and eight bolts (106) to hold ring gear (108) in position.
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     Illustration 101	g00512981

105. Use Tool (K) to install sun gear (105). Install retaining ring (104) on the shaft.
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     Illustration 102	g00514446

106. Install two thrust discs (101), two roller bearings (103), and gear (102) in planetary carrier (98). Install shaft (100) in planetary carrier (98). Repeat this procedure on the four remaining assemblies.
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     Illustration 103	g00514447

107. Install spring pin (99) in shaft (100). Repeat this procedure on the remaining shafts.
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     Illustration 104	g00514448

108. Install two dowels (70) as a guide.
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     Illustration 105	g00514449

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     Illustration 106	g00514450

109. Install five friction discs (91) and four clutch plates (92) on the clutch housing (93).

     Note: Refer to Step 18 for the orientation of the friction discs and the clutch plates.

     Note: The correct seating of clutch plate (U) on the clutch housing is shown in the picture.

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     Illustration 107	g01014185

110. Use Tool (F) and a suitable lifting device to install planetary carrier (98). Planetary carrier (98) weighs 114 kg (251.3 lb).
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     Illustration 108	g00514452

111. Install spacer (97) on planetary carrier (98).
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     Illustration 109	g00514453

112. Install the retaining ring and hub (94) on sun gear (95).
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     Illustration 110	g00512972

113. Install two spring pins (96) on hub (94).
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     Illustration 111	g00514454

114. Use Tool (F) and a suitable lifting device to install hub (94) with sun gear (95) as a unit. The combined weight of hub (94) and sun gear (95) is 20 kg (44.1 lb).

115. Use Tool (J) to install retaining ring (89) on ring gear (90).
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     Illustration 112	g00512944

116. Install 17 bolt dampers (84) in clutch housing (71). Install two balls (85) and four dowels (86).
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     Illustration 113	g00512945

117. Install seal rings (87) and (88) on clutch piston (83).
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     Illustration 114	g00512942

118. Install six long springs (81) and six short springs (82).
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     Illustration 115	g01013849

119. Install clutch piston (83) in clutch housing (71).
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     Illustration 116	g01013846

120. Use Tool (A) and a suitable lifting device to install clutch housing (71). Clutch housing (71) weighs 68 kg (149.9 lb).
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     Illustration 117	g01014195

121. Use Tool (G) and a suitable lifting device to install gear (80) on clutch housing (71). Gear (80) weighs 30 kg (66.1 lb).
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     Illustration 118	g00512937

122. Install two thrust discs (77), two roller bearings (79), and gear (78) in planetary carrier (74). Install governor control shaft (76) in planetary carrier (74). Repeat this procedure on the four remaining assemblies.
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     Illustration 119	g00514456

123. Use a hammer to install spring pin (75) in governor control shaft (76). Repeat this procedure for the four remaining assemblies.
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     Illustration 120	g01013842

124. Use Tool (F) and a suitable lifting device to install planetary carrier (74). Planetary carrier (74) weighs 86 kg (189.6 lb).
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     Illustration 121	g00514458

125. Install seven friction discs (72) and six clutch plates (73) on clutch housing (71).

     Note: Refer to Step 18 for the orientation of the friction discs and the clutch plates.

     Note: Refer to Step 104 for the orientation of one clutch plate.

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     Illustration 122	g00512930

126. Install six springs (67), six pins (68), and six springs (69). Install four remaining dowels (70) on clutch housing (71).
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     Illustration 123	g00512928

127. Install two balls (66) in end housing (64).
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     Illustration 124	g01013838

128. Use Tool (F) and a suitable lifting device to install end housing (64) and two bolts (65) on the transmission. End housing (64) weighs 34 kg (74.9 lb).
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     Illustration 125	g00512924

129. Install O-ring seal (63) on planetary carrier (62).
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     Illustration 126	g00512921

130. Install oil slinger (61), ring (60), ten locking bolts (59), and ten washers on planetary carrier (62).
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     Illustration 127	g00512919

131. Apply gasket material to the contact surface of baffle (58). Install baffle (58). Install 24 bolts (57) and 24 washers on the end housing.
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     Illustration 128	g00512918

132. Raise the temperature of ball bearing (55). Install ball bearing (55) on the transmission. Use Tool (E) to install retaining ring (55).
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     Illustration 129	g00514459

133. Raise the temperature of drive adapter (53). Install drive adapter (53) and four bolts (54).
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     Illustration 130	g00514460

134. Use compressed air to check the operation of the six pistons.
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     Illustration 131	g00512916

135. Install O-ring seal (51) on flange (52) of the transfer gear case.

     Note: The two bolts that hold the transmission case and the transfer gear case to Tool (C) are included in 18 bolts (48) that must be removed. Be careful during the removal of the transmission case from the transfer gear case. Only the weight of the transmission and the transfer gear case is keeping the transmission and transfer gear case on Tool (C).

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     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.

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     Illustration 132	g00512914

136. Remove two bolts (48) and two nuts (49) that hold the transfer gear case to Tool (C). Use Tool (D) and a suitable hoist to lower transmission case (50) on the transfer gear case. Transmission case (50) weighs 227 kg (500.5 lb).
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     Illustration 133	g00512912

137. Install Tool (C). Install remaining 16 bolts (48) and the washers that hold transmission case (50) to the transfer gear case.
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     Illustration 134	g00512911

138. Install 17 bolts (47) in the transmission. Tighten bolts (47) to a torque of 410 ± 50 N·m (302.4 ± 36.9 lb ft).

     Note: During the installation of bolts (47), use a soft hammer to force bolts (47) through the dampers.

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     Illustration 135	g00512909

139. Install four magnets (46) on screen tube assembly (44). Repeat this procedure on the remaining screen tube assembly.
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     Illustration 136	g00512908

140. Install screen tube assembly (44) in suction screen (43). Repeat this procedure on the remaining screen tube assembly.
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     Illustration 137	g00512907

141. Install studs (45) in screen housing (37). Install two suction screens (43) and two screen tube assemblies (44) in screen housing (37).
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     Illustration 138	g00512906

142. Install two seals (42) and two wave washers (41) on screen housing (37).
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     Illustration 139	g00512905

143. Install two covers (40) and eight nuts (39) on screen housing (37).
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     Illustration 140	g00512903

144. Install two O-ring seals (38) on screen housing (37).
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     Illustration 141	g00512901

145. Install screen housing (37) on the transmission case. Install bolt (35) and the washer. Install two bolts (36) on the transmission case.
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     Illustration 142	g00512900

146. Remove two bolts (48) (not shown) that hold the transmission to Tool (C). Use Tool (D) to lift the transmission from Tool (C). Install two bolts (48) (not shown) on the transmission.
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     Illustration 143	g00514462

147. Use a suitable lifting device to place the transmission in a suitable stand.
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     Illustration 144	g00512899

148. Install drive shaft (34) through the transfer case end.
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     Illustration 145	g00514463

149. Install retainer (29). Use a suitable press to install ball bearing (33).
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     Illustration 146	g00512896

150. Install retaining ring (32) on ring (31).
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     Illustration 147	g00512895

151. Align the identifying marks. Install retainer (29) with ring (31), four bolts (30), and the washers on sensor housing (27).
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     Illustration 148	g00512894

152. Install spacer (28), sensor housing (27), five grommets (26), five bolts (25), and the five washers on the transfer case.
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     Illustration 149	g00512893

153. Install yoke (23) and O-ring seal (24) on the transfer gear.
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     Illustration 150	g00512892

154. Install retainer (22) and bolt (21) that holds yoke (23) to the transfer gear.
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     Illustration 151	g00512890

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     Illustration 152	g00512891

155. Remove bolt (19) and the washer. Use bolt (19) and the washer to install Tool (A). Attach a suitable lifting device to Tool (A). Install transmission control valve (20) on the transmission. Transmission control valve (20) weighs 68 kg (149.9 lb).

156. Install four bolts (18) and the four washers on the transmission. Tighten bolts (18) to a torque of 48 ± 4 N·m (35.4 ± 2.9 lb ft).
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     Illustration 153	g00512887

157. Install O-ring seal (16) on flange (15). Install two O-ring seals (17) on sleeve (14). Repeat this procedure for the remaining flange and the sleeve.
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     Illustration 154	g00512866

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     Illustration 155	g00512865

158. Install sleeve (14) on flange (15). Repeat this procedure on the remaining sleeve.

159. Install two flanges (15), sleeves (14), eight bolts (12), and two covers (13) on the transmission case.
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     Illustration 156	g00512862

160. Install the manifold, four bolts (11), and four washers on the transmission case.
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     Illustration 157	g00512860

161. Install gasket (10) on the transmission case.
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     Illustration 158	g00512857

162. Install cover (6), 21 bolts (9), three clips (7), three bolts (8), and three washers on the transmission case.
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     Illustration 159	g00512856

163. Install gasket (5) on cover (6).
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     Illustration 160	g00512855

164. Install cover (4) and ten nuts (3).
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     Illustration 161	g00512854

165. Install step (2). Install four bolts (1) and four washers.

End By:

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