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

Removal Procedure

1. Disconnect the speed sensor wiring from speed sensor assembly (2) .

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Illustration 1	g00512441

2. Remove four bolts (1) and the washers that secure speed sensor assembly (2) to the transfer gear case housing.

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Illustration 2	g00512445

3. Use two 3/8" - 16 NC forcing bolts (3) in order to separate speed sensor assembly (2) from transfer gear case housing (5) . Remove shim pack (4) with speed sensor assembly (2) .

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Illustration 3	g00512447

4. Remove O-ring seal (6) from speed sensor assembly (2) . Remove five bolts (8) , the washers, spacers, rubber mounting washers, cover (7) and gasket (9) from speed sensor assembly (2) . Remove shim pack (4) from speed sensor assembly (2) .

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Illustration 4	g00512451

5. Remove electronic speed sensor pickup (10) from cover (7) .

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Illustration 5	g00512453

6. Remove O-ring seal (15) from electronic speed sensor pickup (10) . Remove four bolts (11) that secure retainer plate (14) to cover (7) . Remove retainer plate (14) , speed sensor gear (13) and shaft (12) as a unit from cover (7) .

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Illustration 6	g00512455

7. Use Tooling (A) in order to remove retaining ring (16) that secures roller bearing (17) to shaft (12) .

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Illustration 7	g00512458

8. Use Tooling (B) in order to remove roller bearing (17) from shaft (12) . Remove retainer plate (14) and speed sensor gear (13) from shaft (12) .

Installation Procedure

1. Inspect all parts and clean all parts. If any parts are worn or damaged, use new Caterpillar parts for replacement.

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Illustration 8	g00512459

2. Install speed sensor gear (13) to shaft (12) . Lower the temperature of shaft (12) . Heat roller bearing (17) . Position retainer plate (14) to shaft (12) . Install roller bearing (17) to shaft (12) .

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Illustration 9	g00512455

3. Use Tooling (A) in order to install retaining ring (16) that secures roller bearing (17) to shaft (12) .

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Illustration 10	g00512453

4. Position retainer plate (14) , speed sensor gear (13) and shaft (12) as a unit in cover (7) . Install four bolts (11) that secure retainer plate (14) to cover (7) .

5. Install O-ring seal (15) to electronic speed sensor pickup (10) . Install electronic speed sensor pickup (10) to cover (7) .

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Illustration 11	g00512447

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Illustration 12	g00512441

6. Position cover (7) and gasket (9) to speed sensor assembly (2) . Install five bolts (8) , the washers, spacers and rubber mounting washers that secure cover (7) to speed sensor assembly (2) .

7. Position sensor assembly (2) to the transfer gear case housing without shim pack (4) and O-ring (6) . Install four bolts (1) that secure speed sensor assembly (2) to the transfer gear case housing.

8. Tighten the bolts to a torque of 5.1 N·m (45 lb in). Measure the gap between the sensor assembly and the transfer gear case housing. Use shims that equal the measurement plus 0.0432 cm (.017 inch) .

9. Remove sensor assembly (2) from the transfer gear case housing. Install shim pack (4) and O-ring seal (6) to speed sensor assembly (2) .

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Illustration 13	g00512441

10. Position sensor assembly (2) to the transfer gear case housing. Install four bolts (1) that secure speed sensor assembly (2) to the transfer gear case housing. Tighten bolts (1) to a torque of 47 ± 9 N·m (35 ± 7 lb ft) .

11. Connect the speed sensor wiring to speed sensor assembly (2) .