784C and 785C Off-Highway Truck Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before the assembly procedure, all parts should be thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble.

1. Verify that all components of the transmission planetary are clean and free of foreign material prior to installation.

2. Inspect all the O-ring seals and the components for wear or damage. If necessary, replace the components and the O-ring seals.

3. Lubricate all the O-ring seals lightly with the lubricant that is being sealed.

4. Lubricate all bores and the bearings lightly with the lubricant that is being sealed.
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   Illustration 1	g00531790

5. Install two O-ring seals (220) onto tube assembly (219).
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   Illustration 2	g03743224

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   Illustration 3	g03743263

6. Install Tooling (N). Position tube assembly (219). Use two bolts (140) to hold the upper flange in position in the locating holes of Tooling (N). Install two bolts (218). Remove two bolts (140) and realign the upper flange of tube assembly (219) with the locating holes on Tooling (N).
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   Illustration 4	g00531787

7. Heat race bearing (217) to a temperature of 135 °C (275 °F).

8. Install race bearing (217) into clutch housing (205).

9. Install seal ring (216) onto clutch housing (205).
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   Illustration 5	g00532173

10. Lower the temperature of roller bearing race (215) to a temperature of −75 °C (−103 °F).

11. Use Tooling (A) to install roller bearing race (215) into cage (212).
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    Illustration 6	g00531786

12. Install metal seal ring (213) and six O-ring seals (214) into cage (212).
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    Illustration 7	g00532175

13. Align the identification marks on cage (212) and clutch housing (205) to the correct position. Use Tooling (A) to install cage (212) to clutch housing (205). The weight of clutch housing (205) is 36 kg (79 lb).
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    Illustration 8	g00531782

14. Install seal ring (211) onto clutch piston (210).
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    Illustration 9	g00531781

15. Install clutch piston (210) into clutch housing (205).
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    Illustration 10	g00531780

16. Install 18 springs (209) into clutch piston (210).
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    Illustration 11	g00531778

17. Install seal ring (208) into balance piston (207).
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    Illustration 12	g00531736

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

18. Position balance piston (207) into clutch housing (205) for installation.

19. Use ten bolts (206) and the washers to install balance piston (207) into clutch housing (205). Tighten ten bolts (206) evenly. Tighten each of the bolts evenly by one revolution before proceeding to the next bolt.
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    Illustration 13	g00532022

20. Install Tooling (B) to clutch housing (205). Attach Tooling (B) to a suitable lifting device and a hoist.

21. Use Tooling (B) and the hoist to install clutch housing (205), the clutch piston, and the cage onto the output shaft as a unit. The weight of clutch housing (205), the clutch piston, and the cage as a unit is 73 kg (160 lb).
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    Illustration 14	g00531730

22. Install ten cup plugs (202) to ring gear assembly (201).
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    Illustration 15	g00532038

23. Install ring gear assembly (201) onto the clutch housing.

24. Install friction disc (203) into the clutch housing.

25. Install clutch plate (204) into the clutch housing.

26. Repeat Steps 23 through 25 for the remaining four friction discs and the three clutch plates.
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    Illustration 16	g00531597

27. Install two dowels (200) to plate (199).
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    Illustration 17	g00531572

28. Use a suitable lifting device to install plate (199) to the clutch housing. The weight of plate (199) is 18 kg (40 lb).
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    Illustration 18	g00532052

29. Position sun gear (197) onto center shaft (198).

30. Use needle nose pliers to compress retaining ring (196). Install retaining ring (196) to install sun gear (197) onto center shaft (198).
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    Illustration 19	g00529149

31. Install dowel (195) to shaft (184).
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    Illustration 20	g00529148

32. Install sleeve bearing (194) to shaft (184).
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    Illustration 21	g00532174

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    Illustration 22	g00531566

33. Use Tooling (A) to install roller bearing race (193) into planetary carrier assembly (185).
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    Illustration 23	g00531561

34. Position planetary carrier assembly (185) onto shaft (184). The weight of planetary carrier assembly (185) is 23 kg (50 lb).

35. Use retaining ring (192) to install shaft (184) to planetary carrier assembly (185).
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    Illustration 24	g00531558

36. Install plug (191) into planetary shaft assembly (187).
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    Illustration 25	g00531556

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    Illustration 26	g00531553

37. Install planetary shaft assembly (187), gear (188), two thrust discs (189), and two roller bearings (190) to planetary carrier assembly (185).

38. Use a suitable drift to install pin (186) into planetary carrier assembly (185) and shaft (184).

39. Repeat Steps 37 through 38 for the remaining three planetary shaft assemblies.
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    Illustration 27	g00532216

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    Illustration 28	g00531547

40. Install Tool (C) to shaft (184). Attach Tool (C) to a suitable lifting sling and a hoist.

41. Use Tool (C) and the hoist to install shaft (184) and planetary carrier assembly (185) as a unit. The weight of shaft (184) and planetary carrier assembly (185) as a unit is 73 kg (160 lb).
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    Illustration 29	g00531431

42. Use eight bolts (181) and four locking plates (182) to install ring gear (183) to the plate assembly.
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    Illustration 30	g00531430

43. Install friction disc (179) onto the ring gear.

44. Install clutch plate (180) onto the ring gear.

45. Repeat Steps 43 through 44 for the remaining four friction discs and the three clutch plates.
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    Illustration 31	g00531428

46. Install six dowels (178) into the ring gear.
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    Illustration 32	g00531425

47. Install two O-ring seals (177) onto tube assembly (174).
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    Illustration 33	g00531417

48. Install O-ring seal (175) and spring pin (176) to plug (173).
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    Illustration 34	g00531422

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    Illustration 35	g00531395

49. Use plug (173) to install tube assembly (174) to the bottom of the transfer case.
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    Illustration 36	g00531394

50. Install two balls (172) into manifold assembly (142).
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    Illustration 37	g00531390

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    Illustration 38	g00531389

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

51. Install valve (171), washer (170), and spring (169) into body (168).

52. Install cap (166) and O-ring seal (167) onto body (168).
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    Illustration 39	g00531386

53. Install lubrication relief valve (164), two O-ring plugs (165), and the two O-ring seals into manifold assembly (142).
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    Illustration 40	g00531383

54. Install two dowels (163) to ring carrier assembly (144).
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    Illustration 41	g00532357

55. Install Tooling (D) to manifold assembly (142). Attach Tooling (D) to a suitable lifting device and a hoist.

56. Use Tooling (D) and the hoist to position manifold assembly (142) onto ring carrier assembly (144). The weight of manifold assembly (142) is 52 kg (115 lb).

57. Use seven bolts (162) to install manifold assembly (142) to ring carrier assembly (144).
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    Illustration 42	g00531375

58. Install two seal rings (160) to ring carrier assembly (144).

59. Align the identification marks on seal adapter (159) with the identification marks on manifold assembly (142). Use seven bolts (161) to install seal adapter (159) onto manifold assembly (142).
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    Illustration 43	g00532366

60. Use Tooling (A) to install ball bearing (157) to clutch housing (145).
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    Illustration 44	g00531368

61. Install seal ring (158) into clutch housing (145).
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    Illustration 45	g00531365

62. Install Tooling (F) to clutch housing (145). Attach Tooling (F) to a suitable lifting device and a hoist.

63. Use Tooling (F) and the hoist to install clutch housing (145) and ball bearing (157) as a unit onto ring carrier assembly (144). The weight of clutch housing (145) and ball bearing (157) as a unit is 45 kg (100 lb).

64. Install seal ring (156) onto clutch housing (145).
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    Illustration 46	g00531362

65. Install retaining ring (155) onto ring carrier assembly (144).
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    Illustration 47	g00531358

66. Install seal ring (154) into clutch piston (153).
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    Illustration 48	g00531335

67. Install clutch piston (153) into clutch housing (145).
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    Illustration 49	g00531333

68. Install 16 springs (152) into clutch piston (153).
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    Illustration 50	g00532417

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    Illustration 51	g00531324

69. Use Tooling (A) to install sleeve bearing (150) to balance piston assembly (148).

70. Install seal ring (151) to balance piston assembly (148).
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    Illustration 52	g00531323

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    Illustration 53	g00587563

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    Illustration 54	g00531250

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

71. Use four bolts (149) and the washers to install balance piston assembly (148). Tighten four bolts (149) evenly. Tighten each of the bolts evenly by one revolution before proceeding to the next bolt.

72. Install Tooling (E) to balance piston assembly (148). Attach Tooling (E) to a suitable lifting device and a hoist.

73. Use Tooling (E) and the hoist to position balance piston assembly (148), as shown. The weight of the balance piston assembly is 113 kg (250 lb).

74. Remove Tooling (E).

75. Install the remaining two bolts (149) and the washers.

76. Install three seal rings (146) and seal ring (147) to ring carrier assembly (144).
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    Illustration 55	g00532429

77. Install Tooling (D) to manifold assembly (142). Attach Tooling (D) to a suitable lifting device and a hoist.

78. Use Tooling (D) and the hoist to position manifold assembly (142), ring carrier assembly (143), and clutch housing (145) onto the shaft assembly as a unit. The weight of manifold assembly (142), ring carrier assembly (143), and clutch housing (145) as a unit is 113 kg (250 lb).

79. Install 16 bolts (144) and the washers. Tighten 16 bolts (144) to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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    Illustration 56	g00530976

80. Use two bolts (140) and the washers to install tube assembly (141) to manifold assembly (142).
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    Illustration 57	g00532626

81. Use Tooling (A) to install ball bearing (138) into clutch housing (130).

82. Install two dowels (139) into clutch housing (130).
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    Illustration 58	g00530972

    Note: Ensure that the O-ring seal is installed below the piston.

83. Position clutch housing (130), as shown. The weight of clutch housing (130) is 45 kg (100 lb).

84. Install retaining ring (137) into clutch housing (130).
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    Illustration 59	g00530969

85. Install seal ring (136) onto clutch piston (131).
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    Illustration 60	g00530967

86. Install ten springs (135) to clutch piston (131).
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    Illustration 61	g00530963

87. Install seal ring (134) onto balance piston (133).
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    Illustration 62	g00530962

88. Align the identification marks on balance piston (133) with the identification marks on clutch piston (131). Position balance piston (133) onto clutch piston (131).
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    Illustration 63	g00530960

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    Illustration 64	g00530956

89. Position clutch piston (131) and balance piston (133) into clutch housing (130) as a unit.
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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

90. Use six bolts (132) and the washers to install clutch piston (131) and balance piston (133) into clutch housing (130). Tighten bolts (132) evenly. Tighten each of the bolts evenly by one revolution before proceeding to the next bolt.
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    Illustration 65	g00532926

91. Install Tooling (B) to planetary carrier (130). Attach Tooling (B) to a suitable lifting device and a hoist.

92. Use Tooling (B) and the hoist to position planetary carrier (130) and clutch piston (131) onto the shaft assembly as a unit. The weight of planetary carrier (130) and clutch piston (131) as a unit is 64 kg (140 lb).
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    Illustration 66	g00530940

93. Install retaining ring (129).
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    Illustration 67	g00534069

94. Use Tooling (F) (not shown) to install retaining ring (125) to the shaft assembly.

95. Install six dowels (126) to the clutch housing.
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    Illustration 68	g00530925

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    Illustration 69	g00530923

96. Install planetary shaft assembly (121), two thrust discs (122), two caged bearings (123), and gear (124) to planetary carrier (109).

97. Use a suitable drift to install spring pin (120) into planetary carrier (109).

98. Repeat Steps 96 and 97 for the remaining three planetary shaft assemblies.
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    Illustration 70	g00534067

99. Use Tooling (A) to install ball bearing (118) into planetary carrier (109).
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    Illustration 71	g00534066

100. Use Tooling (A) and a suitable press to install bearing retainer (119) into planetary carrier (109).
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     Illustration 72	g00530920

101. Install retaining ring (116) onto sun gear (115).

102. Slide hub (117) onto sun gear (115) until retaining ring (116) locks onto the groove on hub (117).
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     Illustration 73	g00530907

103. Position sun gear (115), as shown.

104. Install two seal rings (114) to sun gear (115).
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     Illustration 74	g00530900

105. Install retaining ring (111) onto planetary carrier (109).

106. Install O-ring seal (112) onto bearing retainer (113).
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     Illustration 75	g00534071

107. Use a suitable lifting device (not shown) and a hoist to position sun gear (115) and hub (117) onto the shaft as a unit. The weight of sun gear (115) and hub (117) as a unit is 24 kg (52 lb).
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     Illustration 76	g00534072

108. Install friction disc (127) into the clutch housing.

109. Install clutch plate (128) into the clutch housing.

110. Repeat Steps 108 through 109 for the remaining three friction discs and the two clutch plates.
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     Illustration 77	g00530898

111. Install Tooling (E) to planetary carrier (109). Attach Tooling (E) to a suitable lifting device and a hoist.

112. Use Tooling (E) and the hoist to position planetary carrier (109) onto the sun gear. The weight of planetary carrier (109) is 57 kg (125 lb).

113. Use 12 bolts (110) and the washers to install planetary carrier (109) to the sun gear. Tighten 12 bolts (110) to a torque of 115 ± 7 N·m (85 ± 5 lb ft).
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     Illustration 78	g00530873

114. Install four dowels (107) and two balls (108) into clutch housing (102).
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     Illustration 79	g00530860

115. Install internal seal ring (105) and external seal ring (106) onto clutch piston (104).
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     Illustration 80	g00530858

116. Install clutch piston (104) into clutch housing (102).
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     Illustration 81	g00530855

117. Use a suitable lifting device (not shown) and a hoist to install ring gear (103) into clutch housing (102).
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     Illustration 82	g00533117

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     Illustration 83	g00530850

118. Install Tooling (B) to clutch housing (102). Attach Tooling (B) to a suitable lifting device and a hoist.

119. Use Tooling (B) and the hoist to position clutch housing (102), ring gear (103), and clutch piston (104) as a unit. The weight of clutch housing (102), ring gear (103), and clutch piston (104) as a unit is 118 kg (260 lb).

120. Use 12 bolts (101) and the washers to install clutch housing (102).
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     Illustration 84	g00530849

121. Install friction disc (99) into the clutch housing.

122. Install clutch plate (100) into the clutch housing.

123. Repeat Steps 108 through 122 for the remaining two friction discs and the remaining clutch plate.
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     Illustration 85	g00530848

124. Install 12 springs (97) and six dowels (98) onto the clutch housing, as shown.
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     Illustration 86	g00530846

125. Install two bolt dampers (95) and ball (96) to clutch housing (91).
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     Illustration 87	g00530844

126. Install internal seal ring (93) and external seal ring (94) into clutch piston (92).
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     Illustration 88	g00530843

127. Install clutch piston (92) into clutch housing (91).
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     Illustration 89	g00530791

128. Use a suitable lifting device (not shown) and a hoist to install ring gear (90) into clutch housing (91). The weight of ring gear (90) is 41 kg (90 lb).
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     Illustration 90	g00533363

129. Install Tooling (B) to clutch housing (91). Attach Tooling (B) to a suitable lifting device and a hoist.

130. Use Tooling (B) and the hoist to position clutch housing (91) and ring gear (90) as a unit. The weight of clutch housing (91) and ring gear (90) as a unit is 120 kg (265 lb).
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     Illustration 91	g00530788

131. Use eight bolts (88) and four locking plates (89) to install ring gear (90).
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     Illustration 92	g00533368

132. Position sun gear (97) onto the shaft assembly.

133. Use Tool (G) to install retaining ring (86) onto the shaft assembly.
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     Illustration 93	g00530782

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     Illustration 94	g00530778

134. Install planetary shaft assembly (82), two thrust discs (83), two bearings (84), and gear (85) into planetary carrier (80).

135. Use a suitable drift to install spring pin (81) into planetary shaft assembly (82).

136. Repeat Steps 134 and 135 for the remaining three gears.
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     Illustration 95	g00587400

137. Install Tooling (E) to planetary carrier (80). Attach Tooling (E) to a suitable lifting device and a hoist.

138. Use Tooling (E) and the hoist to install planetary carrier (80) onto the shaft assembly. The weight of planetary carrier (80) is 102 kg (225 lb).
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     Illustration 96	g00530752

139. Install spacer (79) onto planetary carrier (80).
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     Illustration 97	g00587405

140. Install retaining ring (78) (not shown) onto sun gear (76).

141. Slide hub (75) onto sun gear (76) until retaining ring (78) (not shown) locks onto the groove on hub (75).

142. Install two spring pins (77) onto hub (75).
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     Illustration 98	g00587407

143. Install Tooling (E) to hub (75). Attach Tooling (E) to a suitable lifting device and a hoist.

144. Use Tooling (E) and the hoist to position hub (75) and sun gear (76) onto the planetary carrier as a unit. The weight of hub (75) and sun gear (76) as a unit is 23 kg (50 lb).
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     Illustration 99	g00587420

145. Use Tooling (G) to install retaining ring (72) into ring gear assembly (73).

146. Install four dowels (74) into ring gear assembly (73).
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     Illustration 100	g00530735

147. Install friction disc (70) into the clutch housing.

148. Install clutch plate (71) into the clutch housing.

149. Repeat Steps 108 through 148 for the remaining four friction discs and the three clutch plates.
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     Illustration 101	g00541532

150. Install two balls (69) into the clutch housing.

151. Install 17 bolt dampers (68) into the clutch housing.
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     Illustration 102	g00530724

152. Install six springs (67) onto the clutch piston, as shown.

153. Install six springs (66) onto the clutch housing, as shown.
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     Illustration 103	g00533376

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     Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

154. Install Tooling (B) to clutch housing (65). Attach Tooling (B) to a suitable lifting sling and a hoist.

155. Use Tooling (B) and the hoist to position clutch housing (65). The weight of clutch housing (65) is 57 kg (125 lb).
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     Illustration 104	g00530718

156. Install internal seal ring (63) and external seal ring (64) into clutch piston (62).
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     Illustration 105	g00530696

157. Install clutch piston (62) onto the clutch housing.
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     Illustration 106	g00587446

158. Install Tooling (E) to ring gear (61). Attach Tooling (E) to a suitable lifting device and a hoist.

159. Use Tooling (E) and the hoist to position ring gear (61) onto the clutch housing. The weight of ring gear (61) is 34 kg (75 lb).
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     Illustration 107	g00530691

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     Illustration 108	g00530689

160. Install planetary shaft (57), two thrust discs (58), gear (59), and two bearings (60) to planetary carrier (55).

161. Use a suitable drift to install spring pin (56) into planetary carrier (55).

162. Repeat Steps 160 and 161 for the remaining five gears.
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     Illustration 109	g00587457

163. Install Tooling (E) to planetary carrier (55). Attach Tooling (E) to a suitable lifting device and a hoist.

164. Use Tooling (E) and the hoist to install planetary carrier (55) into the ring gear. The weight of planetary carrier (55) is 79 kg (175 lb).
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     Illustration 110	g00530685

165. Install friction disc (53) into clutch housing (52).

166. Install clutch plate (54) into clutch housing (52).

167. Repeat Steps 165 through 166 for the remaining five friction discs and the four clutch plates.
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     Illustration 111	g00530684

168. Install six springs (48), six pins (49), six springs (50), and six dowels (51) onto clutch housing (52), as shown.
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     Illustration 112	g00530681

169. Install ball (47) into end housing assembly (45).
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     Illustration 113	g00587469

170. Install Tooling (E) to end housing assembly (45). Attach Tooling (E) to a suitable lifting device and a hoist.

171. Use Tooling (E) and the hoist to position end housing assembly (45) onto the clutch housing. The weight of end housing assembly (45) is 34 kg (75 lb).
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     Illustration 114	g00530677

172. Install ring (43), oil slinger (44), and the gasket (not shown) to the planetary carrier.

     Note: Install the rubber side of the gasket against the oil slinger.

173. Install 12 locking bolts (42) and the washers.
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     Illustration 115	g00530675

     Note: Apply 7M-7260 Liquid Gasket to baffle (41) prior to installation.

174. Use 24 bolts (40) and the washers in order to install baffle (41) to the end housing assembly.
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     Illustration 116	g00533475

175. Heat ball bearing (39) to a temperature of 135 °C (275 °F).

176. Position ball bearing (39) onto the shaft.

177. Use Tool (J) to install retaining ring (38).
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     Illustration 117	g00534068

178. Use four bolts (36) in order to install adapter (37) to the planetary carrier.
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     Illustration 118	g00533549

179. Install O-ring seal (35) onto the transfer case assembly.
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     Illustration 119	g00533565

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     Illustration 120	g00530666

180. Install Tooling (D) to transmission case (34). Attach Tooling (D) to a suitable lifting device and a hoist.

181. Use Tooling (D) and the hoist in order to position transmission case (34) onto the transfer gear case, as shown. The weight of transmission case (34) is 272 kg (600 lb).

182. Use 17 bolts (32) in order to install transmission case (34). Tighten 17 bolts (32) to a torque of 410 ± 50 N·m (302 ± 37 lb ft).

183. Use 18 bolts (33) and the washers to install transmission case (34) to the transfer gear case.
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     Illustration 121	g00530663

184. Install four magnets (31) to screen tube assembly (29). Repeat this step for the remaining screen tube assembly (29).
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     Illustration 122	g00530662

185. Install two suction screens (28) and two screen tube assemblies (29) to magnetic screen group (22). Install eight studs (30) to magnetic screen group (22).
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     Illustration 123	g00530660

186. Install two wave washers (26) and two O-ring seals (27) to magnetic screen group (22).
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     Illustration 124	g00530659

187. Install two top covers (25) to magnetic screen group (22) with eight nuts (24).
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     Illustration 125	g00530634

188. Install two O-ring seals (23) to magnetic screen group (22).
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     Illustration 126	g00530632

189. Install magnetic screen group (22) to the transmission case with three bolts (21) and the washers.
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     Illustration 127	g00533598

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     Illustration 128	g00530327

190. Remove four bolts (20) and the washers from transmission case (34) and Tooling (K). Use Tooling (E) and a hoist to remove the transmission and transfer gears from Tooling (K) as a unit. The weight of the transmission and the transfer gears is approximately as a unit.

191. Use Tooling (D) and the hoist in order to remove the transmission and transfer gears from Tooling (K). The weight of the transmission and transfer gears is 2040 kg (4500 lb).

192. Position the transmission and transfer gears in the horizontal position on a suitable stand, as shown.
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     Illustration 129	g00533683

193. Install Tool (L) to transmission hydraulic control (19). Attach Tool (L) to a suitable lifting device and a hoist.

194. Use Tool (L) and the hoist to position transmission hydraulic control (19) into the transmission case. The weight of transmission hydraulic control (19) is 64 kg (141 lb).

195. Remove Tool (L) and the hoist.
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     Illustration 130	g00530392

196. Use four bolts (18) and the washers in order to install transmission hydraulic control (19). Tighten four bolts (18) to a torque of 48 ± 4 N·m (35 ± 3 lb ft).
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     Illustration 131	g00530386

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     Illustration 132	g00530385

197. Install O-ring seal (16) onto one-piece flange (14). Install two O-ring seals (17) to sleeve (15).

198. Install sleeve (15) into one-piece flange (14).

199. Repeat Steps 197 through 198 for the remaining one-piece flange and the remaining sleeve.

200. Install two one-piece flanges (14) with two sleeves (15) into the transmission case.
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     Illustration 133	g00530383

201. Use four bolts (10) and the washers in order to install manifold assembly (11) to the transmission case.
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     Illustration 134	g00530382

202. Install gasket (9) onto the transmission case.
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     Illustration 135	g00530381

203. Use 21 bolts (8) to install cover (5) to the transmission case.

204. Install three bolts (7), the washers, and the clips to cover (5).
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     Illustration 136	g00530380

205. Install gasket (6) to cover (5).
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     Illustration 137	g00530379

206. Use ten nuts (3) in order to install cover (4) to cover (5).
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     Illustration 138	g00530378

207. Use four bolts (1) and the washers in order to install guard (2) to the transmission case.

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