| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 128-4773 | Lift Bracket Extension | 1 |
| 128-4775 | Lift Bracket Extension | 1 | |
| B | 6V-7030 | Micrometer Depth Gauge Group | 1 |
| C | 347-3904 | Pilot Pin | 1 |
| 351-0043 | Pilot Pin | 1 | |
| NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
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The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area. |
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At operating temperature, the oil in the power train is hot and under pressure. Hot oil can cause burns. Remove the breather filter cap when the engine is stopped and the breather cap is cool enough to touch by hand. Slowly loosen the breather filter cap in order to release any pressure in the oil tank. Be careful of hot hydraulic oil when any lines are disconnected from the components of the power train. |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Inspect the O-ring seals. If necessary, replace any O-ring seals.
Note: Before the installation of the seals, use 1U-6396 O-Ring Assembly Compound to lubricate the seals.
- Use three M20 bolts to attach Tool (A). Use Tool (A) and a suitable hoist to support differential and bevel gear (8). The weight of the differential and bevel gear is
1185 kg (2612.5 lb) .Note: A manufactured tool is shown in the photo in place of Tool (A).
- Check differential and bevel gear (8) for cleanliness. Remove any foreign material that is present.
- Install O-ring seal (21) (not shown).
Note: Leave two bolts (9) in place to retain differential and bevel gear (8) until Tool (A) is in place. The differential and bevel gear must be supported to avoid personal injury or death.
Show/hide tablePersonal 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.
- Use Tool (A), Tool (C), and a suitable hoist to position differential and bevel gear (8) in the housing. Install two bolts (9), two washers, and two spacers (10) to retain differential and bevel gear (8).
- Remove Tool (A).
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Illustration 2 g00511989 Show/hide table
Illustration 3 g00511994 - Install 26 spacers (10), 26 washers, and 26 bolts (9). Tighten bolts (9) to a torque of
460 ± 60 N·m (339.3 ± 44.3 lb ft) . - Install the two washers and two bolts (20). Tighten bolts (20) to a torque of
460 ± 60 N·m (339.3 ± 44.3 lb ft) . - Install O-ring seal (19) and elbow (18).
- Install O-ring seal (17). Connect hose assembly (16).
- Install O-ring seal (15), the block assembly, and sensor (14). Install O-ring seal (7), hose assembly (6), and split flange (13). Use four bolts (12) and four washers for installation.
- Connect oil temperature sensor (11) of the differential.
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Illustration 4 g00511963 - Install O-ring seal (5) on thrust pin (4). Use a 3/8-NC bolt to install thrust pin (4) in the differential housing.
- Use Tool (B) to measure the gap between thrust pin (4) and the milled surface of the differential housing.
- Calculate the thickness of shim (3). The thickness of the shim should equal the gap in Step 13 minus
.05 ± .02 mm (0.0020 ± 0.0008 inch) .Show/hide table
Illustration 5 g00512300 - Use Tool (B) to adjust shim pack (3) to the thickness that was calculated in Step 14.
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Illustration 6 g00511959 - Install shim pack (3), cover (2), two washers, and two bolts (1). Tighten bolts (1) to a torque of
100 ± 20 N·m (73.8 ± 14.8 lb ft) . - Fill the differential with oil. Refer to Operation and Maintenance Manual for the fluid capacities and the proper filling procedures.
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| Illustration 1 | g00511992 |
End By:
- Install the transmission and transfer gears.
- Install the axle shafts.
- Remove the truck body retaining cable.