793C Off-Highway Truck/Tractor Power Train Caterpillar

Assembly Procedure

Note: For information on reusability of the components of the differential and bevel gear, refer to Guideline for Reusable Parts and Salvage Operations, SEBF8119, "Differential Components for Wheel Loaders, Off-Highway Trucks and Tractors, Articulated Dump Trucks, Wheel Tractors, Compactor, and Integrated Toolcarriers".

Note: For information on the reusability of the pinion gear, refer to Guideline for Reusable Parts and Salvage Operations, SEBF8119, "Differential Components for Wheel Loaders, Off-Highway Trucks and Tractors, Articulated Dump Trucks, Wheel Tractors, Compactors, and Integrated Tool Carriers".

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Illustration 1	g00515345

1. Heat bearing cone (77) and bearing cone (78) to a maximum temperature of 135 °C (275.0 °F). Install bearing cone (77) and bearing cone (78) on pinion gear (72). Verify that the bearing cones have seated against the shoulder of the pinion shaft. Use a standard feeler gauge or a piece of shim stock with a thickness of .05 mm (.002 inch).

   Note: Pinion Gear assembly should now be set aside for a minimum of 12 hours to allow the bearing temperature to equalize.

   Note: Pinion gear (72) weighs approximately 101 kg (220 lb), including bearing cone (77) and bearing cone (78).

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   Illustration 2	g00515435

2. Install carrier housing (37) on a suitable fixture. Install the nominal shim pack (74) on the counterbore of the carrier. The carrier weighs approximately 588 kg (1296.3 lb).

   Note: Shim pack (74) should have a thickness of 9.12 mm (.359 inch).

   Note: A combination of four thicknesses for the shims are used to achieve the correct shim pack in Step 2.

   The following measurements are the thicknesses of the shims:

   8X-0332 Shim ... 3.000 mm (0.1181 inch)

   8X-0333 Shim ... 3.108 mm (0.1224 inch)

   8X-0334 Shim ... 3.203 mm (0.1261 inch)

   106-5027 Shim ... 2.898 mm (0.1141 inch)

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   Illustration 3	g00515437

3. Lower the temperature of bearing cup (73) to −45 °C (−49.0 °F). Use a suitable driver to install the bearing cup in the carrier. Before proceeding, be certain that the bearing cup and the shims are seated against the bottom of the counterbore. To verify that the bearing is seated, use a standard feeler gauge or a piece of shim stock with a thickness of 0.05 mm (0.002 inch).
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   Illustration 4	g00515439

4. Install O-ring seal (75) and O-ring seal (76) on elbow (62). Install elbow assembly (62). Orient the elbow assembly.

5. Install two M12 - 1.75 x 30 guide bolts.
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   Illustration 5	g00515441

6. Install the pinion gear and pinion assembly (72) in the carrier. Lubricate the bearing cones with the fluid that is being sealed.

7. Install two M12 - 1.75 x 30 guide bolts, as shown.
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   Illustration 6	g00515445
   View of pinion bearing cage after rework (D) Distance from reference line (I) ( 47 mm (1.85 inch)) (E) Distance from reference line (F) ( 240 mm (9.45 inch)) (F) Reference line (G) Distance from reference line (F) ( 240 mm (9.45 inch)) (H) Distance from reference line (I) ( 47 mm (1.85 inch)) (I) Reference line

8. If pinion bearing cage (65) does not have two tapped holes, drill into the pinion bearing cage. Tap two 7/16 - 20 class 2A threaded holes in the pinion bearing cage.

   Note: These holes will accept Tooling (A).

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   Illustration 7	g00515448

9. Lower the temperature of bearing cup (69) (not shown) to −45 °C (−49.0 °F). Use a suitable driver to install the bearing cup in pinion bearing cage (65).

10. Before proceeding, be certain that bearing cup (69) is seated against the bottom of the counterbore. To verify that the bearing is seated, use a standard feeler gauge or a piece of shim stock with a thickness of 0.05 mm (0.002 inch).

11. Use Tooling (B) and a suitable lifting device to assemble pinion bearing cage (65) on the carrier.

    Note: Do not install shims (68) (not shown), seal (70) (not shown), and O-ring seal (71) (not shown) between the cage and the carrier.

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    Illustration 8	g00515449
    View of the fabricated drive plate (A2) 1018 steel square tube (A3) 1018 steel plate (Q) Thickness ( 3.0 mm (0.12 inch)) (R) Width ( 100.0 ± 1.0 mm (3.94 ± 0.04 inch)) (S) Length ( 53.5 ± 1.0 mm (2.11 ± 0.04 inch)) (T) Width ( 25.4 mm (1.00 inch)) (W1) There is a fillet weld on both sides. There are four points of penetration with a depth of 3.0 mm (0.12 inch).

12. Fabricate the drive plate of the pinion gear. The drive plate of the pinion gear is part of Tooling (C).
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    Illustration 9	g00515450
    View of the fabricated drive shaft (D1) Rod (D2) Block (D3) 2J-3506 Full Nut (CC) Length ( 289.4 mm (11.39 inch)) (DD) Length ( 247.7 ± 1.0 mm (9.75 ± 0.04 inch)) (EE) Length ( 25.4 ± 1.0 mm (1.00 ± 0.04 inch)) (FF) Thickness ( 12.7 mm (0.50 inch)) (GG) Length ( 152.4 ± 5.0 mm (6.00 ± 0.20 inch)) (HH) Diameter ( 28.6 mm (1.13 inch)) (JJ) Thickness ( 19.05 mm (0.75 inch)) (W1) There is a fillet weld on both sides. There are two points of penetration with a depth of 3.0 mm (0.12 inch).

13. Fabricate the drive shaft of the pinion gear. The drive shaft of the pinion gear is part of Tooling (C).
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    Illustration 10	g00515452
    View of the fabricated spacer (N) Thickness ( 57.2 ± 1.0 mm (2.25 ± 0.04 inch)) (P) Diameter ( 120 mm (4.7 inch))

14. Fabricate the spacer of the pinion gear. The spacer is part of Tooling (C).
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    Illustration 11	g00515453
    View of fabricated plate (B2) 1018 steel plate (B1) 1018 steel plate (U) Thickness ( 6.35 mm (0.250 inch)) (V) Angle between the reference lines (120 degrees) (W) Diameter ( 136.6 mm (5.38 inch)) (X) Width ( 25.4 mm (1.00 inch)) (Y) Diameter ( 241.3 ± 1.0 mm (9.50 ± 0.04 inch)) (Z) Length ( 50.8 ± 0.5 mm (2.00 ± 0.02 inch)) (AA) Thickness ( 19.0 mm (0.75 inch)) (BB) Diameter of a class B hole ( 29.4 mm (1.16 inch)) (W2) There is a fillet weld on both sides. There are three points of penetration with a depth of 3.0 mm (0.12 inch).

15. Fabricate the plate. The plate is part of Tooling (D).
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    Illustration 12	g00515455
    View of the fabricated sleeve (E1) Tube with a 13 gauge wall (AA) Length ( 222.3 ± 1.0 mm (8.75 ± 0.04 inch)) (BB) Diameter ( 19.0 mm (0.75 inch))

16. Fabricate the four sleeves. The four sleeves are part of Tooling (D).
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    Illustration 13	g00515456
    View of the fabricated top plate (C1) 1018 steel plate (C2) Two class A holes with a diameter of 11.0 mm (0.43 inch) (C3) 12 class B holes with a diameter of 14.0 mm (0.55 inch) (MM) Distance from reference line (RR) ( 210.18 mm (8.275 inch)) (NN) Distance from reference line (RR) ( 130.2 mm (5.13 inch)) (PP) Distance from reference line (RR) ( 107.25 mm (4.222 inch)) (RR) Reference line (TT) Distance from reference line (RR) ( 185.76 mm (7.313 inch)) (UU) Distance from reference line (RR) ( 225.98 mm (8.897 inch)) (VV) Thickness ( 19.0 mm (0.75 inch)) (WW) Distance from reference line (EEE) ( 225.98 mm (8.897 inch)) (XX) Distance from reference line (EEE) ( 185.76 mm (7.313 inch)) (YY) Distance from reference line (EEE) ( 210.18 mm (8.275 inch)) (ZZ) Distance from reference line (EEE) ( 107.25 mm (4.222 inch)) (AAA) Distance from reference line (EEE) ( 130.2 mm (5.13 inch)) (BBB) Diameter ( 455.0 mm (17.91 inch)) (CCC) Distance from reference line (EEE) ( 93.6 mm (3.69 inch)) (DDD) Distance from reference line (EEE) ( 87.06 mm (3.428 inch)) (EEE) Reference line (FFF) Diameter of a class B hole ( 29.4 mm (1.16 inch)) (GGG) Diameter ( 519.0 ± 1.0 mm (20.43 ± 0.04 inch)) (HHH) Diameter ( 489.0 mm (19.25 inch)) (JJJ) Distance from reference line (EEE) ( 93.6 mm (3.69 inch)) (KKK) Diameter ( 429.0 mm (16.89 inch)) (LLL) Distance from reference line (EEE) ( 87.06 mm (3.428 inch)) (MMM) Distance from reference line (EEE) ( 107.25 mm (4.222 inch)) (NNN) Distance from reference line (EEE) ( 130.2 mm (5.13 inch)) (PPP) Distance from reference line (EEE) ( 185.76 mm (7.313 inch)) (QQQ) Distance from reference line (EEE) ( 210.18 mm (8.275 inch)) (RRR) Distance from reference line (EEE) ( 225.98 mm (8.897 inch)) (SSS) Distance from reference line (RR) ( 225.98 mm (8.897 inch)) (TTT) Distance from reference line (RR) ( 185.76 mm (7.313 inch)) (UUU) Distance from reference line (RR) ( 87.06 mm (3.428 inch)) (VVV) Distance from reference line (RR) ( 93.6 mm (3.69 inch)) (WWW) Distance from reference line (RR) ( 107.25 mm (4.222 inch)) (XXX) Distance from reference line (RR) ( 130.2 mm (5.13 inch)) (YYY) Distance from reference line (RR) ( 210.18 mm (8.275 inch))

17. Fabricate the top plate. The top plate is part of Tooling (D).
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    Illustration 14	g00515457
    Set up for the adjustment procedure of the differential pinion bearing

18. Install the fabricated spacer and the fabricated drive in order to install part of Tooling (C).

    Note: The fabricated drive should rest on top of the fabricated spacer allowing the spline to engage to the proper depth.

19. Install the fabricated plate on top of the bearing cage assembly. The three metal pads should be seated on bearing cage (65).

20. Place the hydraulic ram on top of the fabricated plate.

21. Install the remainder of Tooling (D). Insert the four threaded rods and the four washers through the fabricated top plate and the fabricated sleeves. Install two of the threaded rods, two washers, and two sleeves next to the lifting eyes. These components should be separated by 180 degrees on the bearing cage. Install the remaining two threaded rods, two washers, and two sleeves. These components should be 90 degrees away from the bolts that are next to the lifting eyes.

22. Install the hydraulic hoses and the controls for Tooling (D). Attach the pressure differential meter, the needle valve, the connecting couplers, the hose assembly, the valved nipple assembly, and the pipe tee to the hydraulic ram.

23. Install the fabricated drive shaft.

    Note: The procedure for setting the bevel pinion bearing should be performed in the vertical position.

24. Apply 18616 ± 345 kPa (2700 ± 50 psi) of hydraulic pressure to Tooling (F). Use Tooling (E) in order to rotate the pinion gear by three revolutions. If the hydraulic pressure drops, increase the hydraulic pressure back to 18616 ± 345 kPa (2700 ± 50 psi) and again rotate the pinion gear by three revolutions. Repeat this procedure until the hydraulic pressure does not drop during rotation of the pinion.

    Note: Rotation of the pinion is critical in order to get proper seating of all components.

25. Completely release pressure in Tooling (D) to 0 kPa (0 psi).

26. Increase the hydraulic pressure in Tooling (D) to 14824 ± 345 kPa (2150 ± 50 psi). Use Tooling (C) in order to rotate the pinion gear by three revolutions. If the hydraulic pressure drops, increase the hydraulic pressure back to 14824 ± 345 kPa (2150 ± 50 psi) and again rotate the pinion gear by three revolutions. Repeat this procedure until the hydraulic pressure does not drop during rotation of the pinion.

27. Use the following steps as an alternate method to seat bearing cone (77) and bearing cone (78).

    Note: Skip to Step 28 if this alternate method is not used.

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    Illustration 15	g03759180

    1. Install four new bolts (64) and four washers (64B) at Locations (X), in a 90 degree pattern, with two of bolts (64) located near the pinion bearing cage lifting eye holes.

       (64) 6V-5684 Bolt

       (64B) 5P-8245 Hard Washer

    2. Tighten bolts (64) in a crisscross pattern starting with the bolts that are 90 degrees from the pinion bearing cage lifting eye holes. Tighten bolts (64) to a torque of 40 ± 5 N·m (30 ± 4 lb ft) while rotating the pinion by three revolutions.

    3. Retighten bolts (64) to a torque of 40 ± 5 N·m (30 ± 4 lb ft) while rotating the pinion by three revolutions again.

    4. Repeat Step 27.b and Step 27.c until bolts (64) no longer rotate at 40 ± 5 N·m (30 ± 4 lb ft).

    5. Remove bolts (64) and washers (64B). Reinstall bolts (64), hand tight, without the washers.

    6. Begin tightening bolts (64) in small increments in order to pull the pinion bearing cage down evenly. Rotate the pinion by three revolutions. Tighten bolts (64) in small increments in the crisscross pattern to 30 ± 5 N·m (266 ± 44 lb in) and rotate the pinion by three revolutions.

    7. Repeat Step 27.f three more times or until bolts (64) no longer rotate at 30 ± 5 N·m (266 ± 44 lb in).

    8. Continue to Step 28
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    Illustration 16	g00515458
    View of a 6V-6106 Dial Indicator that is zeroed (A) 6V-6106 Dial Indicator (79) 122-0449 Rod Sleeve Extension (80) 5P-4160 Contact Point

28. Install 122-0449 Rod Sleeve Extensions (79) in the pinion bearing cage. Attach 5P-4160 Contact Points (80) to 6V-6106 Dial Indicators (A). Install two 6V-6106 Dial Indicators (A) in the pinion bearing cage.

29. Record the average measurement from Tooling (A).

30. Use the average measurement that was recorded in Step 29 plus 0.352 ± 0.02 mm (0.014 ± 0.001 inch) to determine shim pack (68) (not shown).
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    Illustration 17	g00515459

31. Remove Tooling (A), (C), and (D).

    Note: If the alternate method was used, remove the four bolts and the four washers.

32. Use Tooling (B) and a suitable lifting device to remove pinion bearing cage (65). Place the pinion bearing cage on a suitable bench.

    Note: Use two 12 mm x 1.75 thread forcing screws in order to separate the cage from the carrier.

33. Place the pinion bearing cage on a suitable bench. Turn over the pinion bearing cage.
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    Illustration 18	g00515461

34. Apply Tooling (M) to the counterbore of the lip seal. Remove the spring from the lip seal. Install the lip seal. After the installation of the lip seal, replace the seal spring. Lubricate the sealing surface of the lip seal with the fluid that is being sealed.

35. Lubricate the pinion gear of the wear sleeve with the fluid that is being sealed. Install the wear sleeve on the pinion gear. After the installation of the wear sleeve, lubricate the sealing surface of the wear sleeve with the fluid that is being sealed.

36. Install O-ring seal (71) on the cage. Lubricate the O-ring seal with the fluid that is being sealed.
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    Illustration 19	g00515463

37. Install O-ring seal (66) and O-ring seal (67) on elbow (61). Install elbow (61). Orient elbow (61), as shown.
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    Illustration 20	g00515464

38. Assemble the required number of shims (68). The required number of shims was determined in Step 30.
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    Illustration 21	g00515487

39. Install shims (68) on the carrier.
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    Illustration 22	g00515489

40. Use the fluid that is being sealed to lubricate the pinion gear, the bearing, and the face of the carrier.
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    Illustration 23	g00515491

41. Use Tooling (B) (not shown) and a suitable lifting device to install pinion bearing cage (65) in the carrier. Install four new bolts (64) and the washers. Position the bolts in an equally spaced pattern. Tighten the bolts to a torque of 40 N·m (29.5 lb ft). Tighten the bolts in the following pattern: (X), (Z), (Y) and (W).

    Note: Do not reuse bolts (64). Always use new bolts when the pinion bearing cage is removed.

42. Install four bolts (64) and four washers. Position the bolts in an equally spaced pattern.

43. Use Tooling (C) (not shown) to rotate the pinion gear and the bearing by three revolutions.

44. Install 13 remaining new bolts (64) and 13 washers. Tighten each bolt in a sequential manner to a torque of 50 N·m (36.9 lb ft). Continue to tighten the bolts in a sequential pattern until all the bolts are stabilized at 50 N·m (36.9 lb ft). Tighten each bolt by an additional 60 degrees.
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    Illustration 24	g00515496

45. Install hose (63).
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    Illustration 25	g00515497

46. Check the depth of the pinion according to the following steps:

    1. Position Tooling (F) on Tooling (G). Adjust the dial indicator on Tooling (G) to zero.

    2. Position Tooling (G) and Tooling (F) on the end of the pinion.

    3. Rotate the gauge to the saddle for the differential. The difference between the reading in the saddle and the reading at the zero point must be within 0.13 mm (0.005 inch). If the indicator reading is not within this tolerance, disassemble the pinion. Repeat Steps 2 through 45. Use the difference between the reading in the saddle and the reading at the zero point to adjust the thickness of the shims in Step 2. Shims (68) must be adjusted by the same amount in order to maintain the bearing preload.
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    Illustration 26	g00515499

47. If large housing (48) has been replaced, the holes in the flange must be reamed in order to match the holes in the bevel gear. Use the following procedure to ream the holes in the flange of the large housing:

    1. Use a suitable lifting device to position large housing (48) under bevel gear (60). The housing weighs approximately 95 kg (209.4 lb). The bevel gear weighs approximately 98 kg (216.1 lb).

    2. Use the bevel gear as a guide to ream one hole to a diameter of 20.268 ± .013 mm (.7980 ± .0005 inch).

    3. Install bolt (58) (not shown), a washer, and nut (59) in the reamed hole.

    4. Use the same procedure to install another bolt by at least 180 degrees away from the first bolt.

    5. Ream the remaining holes to a diameter of 20.268 ± .013 mm (.7980 ± .0005 inch).
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       Illustration 27	g00515501

    6. Install the washers, remaining 28 new bolts (58), and 28 nuts (59). Select four bolts (58) that separated by a distance of 90 degrees. Tighten the bolts to torque of 440 ± 40 N·m (324.5 ± 29.5 lb ft). Proceed in a sequence around the bolt pattern. Tighten the remaining bolts to a torque of 440 ± 40 N·m (324.5 ± 29.5 lb ft).

48. New holes must be drilled through the housing flange if the bevel gear needs to be replaced and the existing large housing will be reused. For the correct procedure, refer to Special Instructions. For the 793C Truck, the holes must be reamed to a diameter of 20.268 ± .013 mm (.7980 ± .0005 inch).

    Note: New bolt holes may be drilled in a housing flange one time. Replace the differential housing if the new holes have been made and the bevel gear still fails.

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    Illustration 28	g00515502

49. Install the large housing and the bevel gears on a suitable stand. Lubricate the counterbore of the large housing with Tooling (N).
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    Illustration 29	g00515504

50. Install thrust washer (44) on the dowels in the large housing.

    Note: The dowels must be below the outside face of the thrust washer.

    Note: For information on reusability of the thrust washer, refer to Guideline for Reusable Parts and Salvage Operation, SEBF8183, "Salvage of Finial Drive and Differential Thrust Washers Used in Off-Highway Trucks, Tractors, and Wheel Loaders".

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    Illustration 30	g00515505

51. Install output gear (45) in the proper position on the thrust washer. The output gear weighs approximately 28 kg (61.7 lb).

    Note: For information on reusability of the output gear, refer to Guideline for Reusable Parts and Salvage Operation, SEBF8119, "Differential Components for Wheel Loaders, Off-Highway Trucks and Tractors, Articulated Dump Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers".

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    Illustration 31	g00515506

52. Assemble pinion gear assemblies (47) in the following manner:

    1. Install bearing cup (52) and bearing cup (53) in pinion gear assembly (47).

       Note: For information on reusability of the pinion gear, refer to Guideline for Reusable Parts and Salvage Operation, SEBF8119, "Differential Components for Wheel Loaders, Off-Highway Trucks and Tractors, Articulated Dump Trucks, Wheel Tractors, Compactors, and Integrated Toolcarriers".

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       Illustration 32	g00515507

    2. Install retainer (54), bearing cone (55), and spacer (56) on Tooling (H).
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       Illustration 33	g00515509

    3. Install the pinion gear assembly.
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       Illustration 34	g00515510

    4. Place bearing cone (51) in the proper position.
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       Illustration 35	g00515511

    5. Install lock (50). The lock fits into a slot in the retainer.
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       Illustration 36	g00515512

    6. Install nut (49).
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       Illustration 37	g00515514

    7. Rotate the pinion gear assembly while the nut is tightened with Tooling (J). Tighten the nut to a torque of 70 ± 15 N·m (51.6 ± 11.1 lb ft).

       Note: A manufactured tool is shown in the photo.

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       Illustration 38	g00515515

    8. Bend the two tabs on the lock against the nut.

    9. Repeat this procedure for the remainder of the three pinions.
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    Illustration 39	g00515516

53. Install four pinion gears (47) on spider (46).
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    Illustration 40	g00515517

54. Install the spider and the pinions in the large housing, as shown. In the retainer, the slots should be positioned perpendicular to the mating face of the large retainer. The spider and the pinion gear weigh approximately 50 kg (110.2 lb).

    Note: For information on reusability of the differential housing assembly, refer to Guideline for Reusable Parts and Salvage Operation, SEBF8227, "Salvage of Differential Housing Assembly Used on 785, 789, 793 Trucks".

55. Install output gear (45).
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    Illustration 41	g00515518

56. Apply Tooling (N) to the counterbore of small housing (43).
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    Illustration 42	g00515521

57. Install thrust washer (44) on the dowels in the small housing.

    Note: Tooling (N) is used to retain the thrust washer during the assembly procedures.

    Note: The dowels must be below the outside face of the thrust washer.

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    Illustration 43	g00515523

58. Install small housing (43) on the large housing (48). During assembly, thrust washer (44) (not shown) must remain in the proper position on the two dowels of the thrust washer. The four dowels in the bores for the spider must engage the slots in the four retainers for the pinion bearings. Small housing (43) weighs approximately 43 kg (94.8 lb).

59. Install eight bolts (42) and the washers. Tighten the bolts to a torque of 1000 ± 125 N·m (738 ± 92 lb ft).
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    Illustration 44	g00515524

60. Position the differential housing so the differential gears can be rotated by one of the output gears. The bevel gears and the differential weigh approximately 288 kg (634.9 lb).

61. Use Tooling (C) to turn one of the output gears by two revolutions in a clockwise direction. Then, use Tooling (C) to turn one of the output gears by two revolutions in a counterclockwise direction. The maximum torque that is required to turn the output gear must not exceed 35 N·m (25.8 lb ft).

    Note: A manufactured tool is shown in the photo in order to rotate the differential.

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    Illustration 45	g00515525

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    Illustration 46	g00515527

62. Heat the bearing cone to a maximum temperature of 135 °C (275.0 °F). Install bearing cone (41) on the small housing. Seat the bearing against the shoulder of the housing.

    Note: A manufactured tool is shown in the photo in order to drive the bearings.

63. Lubricate the bearing cone with the fluid that is being sealed.
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    Illustration 47	g00515528

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    Illustration 48	g00515529

64. Reposition the bevel gears and the differential. Heat the bearing cones to a maximum temperature of 135 °C (275.0 °F). Install bearing cone (57) on the large housing. Seat the bearing against the shoulder of the housing.

65. Lubricate the bearing cone with the fluid that is being sealed.
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    Illustration 49	g00515531

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    Illustration 50	g00515532

66. Assemble cage (39), bearing cup (40), and adjusting ring (38) for the small bearing. The combined weight of the small cage, the bearing cup, and the adjusting ring is 12 kg (26.5 lb).

    Note: For information on the salvage of the bearing cage, refer to Guideline For Reusable Parts and Salvage Operations, SEBF8200, "Salvage of Differential Bearing Cage Used on Off-Highway Trucks".

    Note: For information on the reusability of the bearing cups for the small bearing and the large bearing, refer to Guideline For Reusable Parts and Salvage Operations, SEBF8190, "Tapered Bearings Used in Off-Highway Trucks".

67. Assemble the cage, the bearing cup, and the adjusting ring for the large bearing. The weight of the large cage, the bearing cup, and the adjusting ring is approximately 23 kg (50.7 lb).
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    Illustration 51	g00515534

68. Position the ring and adjusting nut assemblies (36) for the two bearing supports into saddles in carrier (37). Position the dowel in the cage so the dowel will enter the bearing cap.
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    Illustration 52	g00515600

69. Position the differential housing and the bevel gear into the bearing cones that are on the carrier.

70. Install bearing cap (31), bracket (29), two washers, and two bolts (30). Tighten the bolts to a torque of 14 N·m (10.3 lb ft).

    Note: The low torque for bolts (30) is to allow for adjustments to be made. A final torque will be applied to bolts (30) in Step 90.

71. Repeat Step 70 for remaining bearing cap (34).
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    Illustration 53	g00515602

72. Position the differential and the carrier so the bevel gear is horizontal and the teeth are facing upward.
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    Illustration 54	g00515604

73. Put Tooling (F) on the teeth of the carrier and the bevel gear.
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    Illustration 55	g00515605

74. Use Tooling (K) in order to turn the larger adjusting ring. Turn the adjusting ring until there is a backlash of .51 ± .13 mm (0.020 ± 0.005 inch) between the bevel gear and the pinion gear. Measure the backlash at intervals of 90 degrees.

    Note: The axle is horizontally oriented for photographic purposes. Usually, the axle is vertically oriented.

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    Illustration 56	g00515606

75. Remove Tooling (F) (not shown). Use Tooling (C) to rotate the pinion gear by three revolutions.

    Note: A manufactured Tooling is shown in the photo instead of Tooling (C).

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    Illustration 57	g00515628
    (X) Dimension (Y) Small adjusting ring

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    Illustration 58	g00515629

76. Position Tooling (F) on the differential and the carrier.

77. Use Tooling (L) (not shown) to turn the smaller adjusting ring. Turn the adjusting ring until dimension (X) increases by .75 ± .05 mm (0.029 ± 0.002 inch). This procedure will set the bearing preload.
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    Illustration 59	g00515606

78. Remove Tooling (F) (not shown). Use Tooling (C) to turn the bevel gears by several revolutions in each direction. Turning the bevel gears will determine that the bearings are seated.

    Note: If the bearing preload is set, the backlash will increase by approximately 0.18 mm (0.007 inch). Backlash must be readjusted to .51 ± .13 mm (0.020 ± 0.005 inch). If the large adjusting ring and the small adjusting ring are moved by the same distance and in the same direction, the backlash can be adjusted while the same bearing preload is maintained.

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    Illustration 60	g00515604

79. Position Tooling (F) on the teeth of the carrier and bevel gear.

80. In order to adjust the backlash between the pinion gear and the bevel gear, turn the adjustment rings by the same amount and in the same direction. The backlash must be .51 ± .13 mm (0.020 ± 0.005 inch).
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    Illustration 61	g00515629

81. Position Tooling (F) in the same manner that was described in Step 76. Use Tooling (L) to turn out the small adjusting ring in order to remove all the preload on the bearings.

82. Use Tooling (L) (not shown) to turn in the small adjusting ring until dimension (X) increases by .50 ± .05 mm (0.019 ± 0.002 inch).
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    Illustration 62	g00515604

83. Position Tooling (F) on the teeth of the carrier and the bevel gear.

84. Check the backlash between the pinion gear and the bevel gear. If the backlash is not within .51 ± .13 mm (0.020 ± 0.005 inch), repeat Step 80.

85. After the adjustments for the backlash and the differential preload are done, check the contact of the teeth between the bevel gear and the pinion. Use the following procedure to check the contact:

    1. Put a small amount of Prussian Blue, red lead, or paint on the bevel gear teeth. Turn the pinion. Inspect the marks that were made on the bevel gear teeth.
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    Illustration 63	g00515630
    Correct Tooth Contact: Reverse (Concave side of gear)

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    Illustration 64	g00515635
    Correct Tooth Contact: Forward (Convex side of gear)

86. If the contact pattern does not match the illustration, the number of shims that was determined in Step 2 must be increased or decreased accordingly The shims from Step 39 must be adjusted by the same amount in order to maintain the bearing preload.

    Note: Several adjustments of the pinion gear and the bevel gear may need to be made before the backlash and the tooth contact are correct. Any alteration of the backlash will change the tooth contact. The backlash must be correct before the tooth contact is checked.

87. The backlash must be checked if shims were added or removed. Repeat Steps 73 through 86.
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    Illustration 65	g00515636

88. Apply Tooling (P) to bolts (32). Install two locks (33), two bolts (32), and two washers that keep the adjustment rings from turning.
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    Illustration 66	g03321600

89. Install two bolts (28) and two washers to install shroud (27).

90. Tighten bolts (30) to a torque of 1600 ± 150 N·m (1180.1 ± 110.6 lb ft).

    Note: A manufactured torque wrench is shown in the photo.

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    Illustration 67	g00515639

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    Illustration 68	g00515641

91. Install fitting (22) and three fittings (26). Install tube (23).

92. Use one bolt (19), the washers, and clip (20) to install tube (21).

93. Use three bolts, three washers, and three clips to install tube (24).

94. Position the bracket at the base of the shroud. Install bolt (25) and the washer. Before installation, apply Tooling (P) to bolt (25).
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    Illustration 69	g00515642

95. Use 12 bolts (18) and 12 washers to install gear (17). The weight of the gear is approximately 10 kg (22.1 lb).
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    Illustration 70	g00515643

96. Use four bolts (14) and four washers to install pump (15). The weight of the pump is approximately 15 kg (33.1 lb).

97. Use washer (11), slotted nut (12), and cotter pin (13) to install gear (10).
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    Illustration 71	g00515646

98. Position Tooling (F) on the pump and the gear teeth. Use shims (16) to obtain a backlash of .37 ± .13 mm (0.015 ± 0.005 inch) between the gears. When this procedure is complete, remove Tooling (F).
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    Illustration 72	g00515669

99. Position pump outlet passage (2) so that O-ring seal (4) is at the flange end and so O-ring seal (5) is at the tube end. Install four bolts (3) and four washers.
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    Illustration 73	g00515671

100. Position pump inlet passage (6) with O-ring seal (8) (not shown) on the flange.

101. Use four bolts (7) and four washers to connect the flange end of the tube to the pump. Use two bolts (9) and two washers to connect the bracket on the strainer to the pump, the differential, and the carrier. Apply Tooling (P) to bolts (7).

End By:

1. Install the differential and bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Install".