D400E Series II Articulated Truck Power Train Caterpillar

Assembly Procedure

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

2. Pay attention to all location marks on all housings and case assemblies for assembly purposes.
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   Illustration 1	g00517781

3. Heat bearing cone (46) to a maximum of 135 °C (275 °F). Install bearing cone (46) on pinion shaft (38).

   Note: Reset bearing cone (46) with a suitable driver after the mating parts have reached a uniform temperature.

   Note: Bearing cone (46) may be pressed on pinion shaft (38). The bearing cone does not need to be heated.

   Note: Bevel gear and pinions are sold in matched sets. You should use only matched sets when you are replacing the bevel gear and pinions.

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   Illustration 2	g00520173

4. Shims are located under bearing cup (45). The thickness of the shim pack will not need to be changed if you are not changing the bevel gear and pinion. The shims are needed in order to properly set up the bevel gear and pinion . The initial thickness of the shim pack must be calculated. First, if you are installing a new bevel gear set into the existing carrier assembly, obtain the "HD" number from the end of the old pinion shaft. Obtain the "HD" number from the end of the new pinion shaft. Subtract the new "HD" from the old "HD". If the answer is negative, you must remove an equivalent thickness of shims from the existing shim pack. If the answer is positive, you must add an equivalent thickness of shims to the existing shim pack. If the answer is zero, you should reuse the existing shim pack.

5. If you are installing an old bevel gear set into a new carrier assembly, obtain the "DC" number from the new carrier assembly. The number (DC) is stamped under the bearing cap. Obtain the "DC" from the old carrier assembly. Subtract the new "DC" number from the old "DC" number. If the answer is negative, remove an equivalent thickness of shims. If the answer is positive, add an equivalent thickness of shims.

6. If you are replacing both the carrier assembly and the bevel gear set, use an initial shim pack of 1.5 mm (.06 inch).

7. Install the shim pack. Press the bearing cup (45) into the carrier. Check the seating of the cup against the shim pack. Lubricate the bearing cup with specified lubricant.

   Note: You may cool bearing cup (45). Seat the bearing cup with a suitable driver once the mating parts have reached a uniform temperature.

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   Illustration 3	g00514962

8. Lubricate bearing cone (46) with clean oil before you install pinion shaft (38). Install pinion shaft (38) in the differential assembly.

9. Install tooling (E).

10. Install two bearing caps (44). Install the bolts and the washers in order to hold tooling (E) in place.

11. Tooling (E) has an adjustment screw which should be adjusted in order to hold pinion shaft (38) in place.
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    Illustration 4	g00521173

12. Lower the temperature of bearing cup (54). Install bearing cup (54) in bearing cage (41). The bearing cup is a press fit after the temperature of the bearing cup has reached room temperature. Lubricate the bearing cup with clean oil.

    Note: Reset the bearing cup with a suitable driver after the mating parts have reached a uniform temperature.

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    Illustration 5	g00524234

13. Rotate the differential assembly by 180 degrees. Check the seal for the bearing cage. Replace the seal if the seal is damaged. Install bearing cage (41).
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    Illustration 6	g00524236

14. Install ten bolts (43) in bearing cage (41).
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    Illustration 7	g00517160

15. Install bearing (40) on pinion shaft (38). Lubricate the bearing with clean oil.
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    Illustration 8	g00514966

16. Install washer (39) on pinion shaft (38).
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    Illustration 9	g00524242

17. Place a wrench on nut (37). Install yoke (30) on splined pinion shaft (38). The yoke is shown in Step 21. Hold yoke (30) with a wrench. Install nut (37) with the other wrench. Tighten nut (37) until the play is out of the bearings of pinion shaft (38).

    Note: Do not make the nut too tight. The pinion bearing preload must be set.

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    Illustration 10	g00517817

    Note: Nut (37) may be reused if the collar is not cracked during removal or restaking.

18. Remove the yoke. Install retaining bolt (31) for the yoke. Use Tooling (B) in order to tighten bolt (31) until pinion shaft (38) turns. Record the torque that is required in order to turn pinion shaft (38). The torque that is required to turn pinion shaft (38) should be 0.67 N·m (5.93 lb in) to 1.35 N·m (12 lb in). Adjust nut (37) until the proper preload for the bearings is obtained.

    Note: If the rolling torque exceeds the specification, back off nut (37). Perform Step 18 again. Check the pinion. The pinion should have no end play.

    Note: The torques that are specified are for new bearings. For used bearings, limit the applied torque to one-half of the specified torque in Step 18.

    Note: Rotation of the pinion is critical. Rotate the pinion in order to seat the bearings.

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    Illustration 11	g00514948

19. Install seal (36) in seal housing (35). Use a properly sized seal driver for proper installation. The lip of the seal should face outward. Apply clean oil to the lips of seal (36).
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    Illustration 12	g00514946

20. Install seal retainer (35) with six bolts (34) on differential carrier assembly (2). Inspect the old gasket. Replace the gasket if the gasket is damaged.
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    Illustration 13	g00514945

21. Install bolt (31) in order to secure yoke (30) on differential carrier assembly (2).
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    Illustration 14	g00514952

22. Rotate differential assembly (2) by 180 degrees. Remove the four bolts in order to remove bearing caps (14). Remove Tooling (E).
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    Illustration 15	g00514943

23. Install thrust washer (29) on bevel gear (28). Apply a light coat of 6V-4876 Lubricant to the thrust surface of the bevel gear before the thrust washer is installed.
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    Illustration 16	g00514942

24. Install bevel gear (28) into housing (20).

    Note: Line up the tabs which are on washer (29) with the spaces within housing (20)

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    Illustration 17	g00514940

25. Apply a light coat of 6V-4876 Lubricant on the bore surface of the pinion gears. Install pinion gears (25) on the shafts (26). Apply a light coat of 6V-4876 Lubricant on the thrust surface of the pinion gears. Install thrust washers (27) onto shafts (26).
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    Illustration 18	g00514939

26. Install gears (25), shafts (26) and thrust washers (27) into housing (20). Match the cut out areas of the shafts together.
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    Illustration 19	g00514937

27. Install bevel gear (24) into housing (20). Install thrust washer (23) onto bevel gear (24). Apply a light coat of 6V-4876 Lubricant to the thrust surface of the bevel gear before the thrust washer is installed.

    Note: The tabs on washer (23) must line up with the spaces that are provided in hub (22).

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    Illustration 20	g00514935

28. Install hub (22) onto housing (20). Rotate the differential case by 180 degrees. Install 12 bolts (21) that secure housing (20) of the differential case to the hub (22) of the differential case. Tighten bolts (21) to a torque of 270 ± 40 N·m (200 ± 30 lb ft) after all internal parts are in place.
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    Illustration 21	g00518401

29. Heat bearing cone (17) to a maximum of 135 °C (275 °F). Install bearing cone (17) on housing (15). Allow bearing cone (17) to cool before you rotate housing (15).

    Note: Reset the bearing cone with a suitable driver after the mating parts have reached a uniform temperature.

30. Rotate housing (15) by 180 degrees. Follow the procedure that is outlined in Step 29 in order to install the other bearing cone (17).
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    Illustration 22	g00518431

31. Perform the following in order to install bevel gear (19) to housing (15).

    Note: New bolts and new hard washers should be installed to secure bevel gear (19).

    1. Heat bevel gear (19) to a temperature between 70 °C (158 °F) and 120 °C (248 °F) in order to install the bevel gear to housing (15).

    2. Install bevel gear (19) to housing (15). Immediately install four bolts and hard washers into bevel gear (19). Install the bolts so that the bolts are spaced equally at 90 degrees. Install the hard washers with the flat face against the housing. Tighten the bolts to a torque of 70 N·m (50 lb ft). Ensure that the bevel gear is properly sealed against the housing.

    3. Loosely install the remaining bolts and hard washers for bevel gear (19). Ensure that the flat face of the hard washers is against housing (15).

    4. Allow bevel gear (19) to cool to approximately 30 °C (86 °F). After the bevel gear has cooled to the required temperature, loosen the four bolts that were tightened earlier.

       Note: If the four initially tightened bolts are not loosened before the final torquing, the joint will not reach a full press fit.

    5. Tighten all the bolts for bevel gear (19) in a star pattern. Mark each bolt after the bolt has been tightened. Tighten the bolts to a torque of 70 ± 10 N·m (52 ± 7.5 lb ft).

    6. Tighten the bolts for bevel gear (19) by an additional 60 degrees.
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    Illustration 23	g00519602

32. Tooling (G) may be used in order to check the temperature of the components.
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    Illustration 24	g00511445

33. Attach a lifting strap to differential carrier (15). Lubricate the rollers for the bearings with clean oil. Install bearing cages (16). Lower differential carrier (15) into the differential carrier. Hold bearing cages (16) in place. Lower differential carrier (15) into place.

    Note: New bearing cups must be installed in bearing cages (16) if new bearings (17) have been installed.

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    Illustration 25	g00519772

34. Install bearing caps (14) with the bolts and washers. Tighten one bolt of each bearing cap (13) to a torque of 70 ± 5 N·m (51 ± 4 lb ft). Tighten the remaining two bolts to a torque of 5.0 N·m (4.0 lb ft).

35. The bearing cups have adjusting nuts (49). Adjusting nuts (49) are used for setting the bearing end play. Adjusting nuts (49) are used for setting the backlash of bevel gear (19). Remove two bolts and lock (48) on each of the adjusting nuts.
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    Illustration 26	g00520906

36. Install Tooling (I). Advance adjusting nuts (49) until bevel gear backlash is eliminated. Maintain slight bearing end play. Rotate the differential assembly by 90 degrees so that the pinion is in a HORIZONTAL position. Install Tooling (B). Measure the torque that is required to rotate the pinion shaft. Record the measured torque.

37. Advance the adjusting nut that is adjacent to the bevel gear. Oscillate the bevel gear. Find a zero backlash position. Then back off the adjusting nut to the nearest lock position. Only back off one lug on the adjusting nut. Notice that there are two lock positions that are available on each adjusting nut (49).

38. Advance the adjusting nut opposite the bevel gear. Monitor the torque that is required in order to rotate the pinion shaft. Look for a torque increase that is over the torque that is measured in Step 18. Tighten the adjusting nut which is opposite the bevel gear. Tighten the adjusting nut until the lock can be installed. Do not install lock (48) until you have finished all adjustments.

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

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    Illustration 27	g00521349

39. Install Tooling (H). Measure the backlash of bevel gear (15). The backlash should be 0.30 ± 0.10 mm (.012 ± .004 inch). Assume that the measurement does not meet the specification. Retract one nut. Advance the other nut. Maintain bearing preload.

40. Remeasure the rolling torque at the pinion shaft in order to verify the correct preload after setting the backlash. The rolling torque should be 1.2 N·m (10.6 lb in) to 2.5 N·m (22.0 lb in). This reading is above the reading that is found in Step 18.
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    Illustration 28	g00521367
    Illustration A

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    Illustration 29	g00521369
    Illustration B

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    Illustration 30	g00521370
    Illustration C

41. The tooth contact between the bevel pinion and gear must be checked. Coat some of the bevel gear teeth with a rouge compound. Turn the bevel pinion shaft in both directions. The correct area of tooth contact starts near the inside of the teeth of the bevel gear. See Illustration (A). If the tooth contact looks like Illustration (B), some shims will need to be added. Recheck the tooth contact. If the tooth contact looks like Illustration (C), some shims will need to be removed. Recheck the tooth contact. If the shim pack has been changed, the backlash will need to be rechecked. See Step 38.
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    Illustration 31	g00514964

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    Illustration 32	g00335136

42. Lock the nut. Peen the nut collar. Proper peening requires the use of a spherical nose punch with a spherical radius (E) of 8 ± 0.5 mm (.31 ± .02 inch). Best results are obtained by holding the punch against the nut face at 10 to 30 degrees with respect to nut face (F). The desired results are a stake that is 4.70 mm (.18 inch) minimum length (G) and 2.5 mm (.1 inch) minimum depth (H).

43. Install lock (48). Apply 1E-3263 Thread Lock to the bolts of lock (48) before installation.
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    Illustration 33	g00557304

44. After the proper backlash has been obtained, tighten two bearing cap bolts (56) to a torque of 530 ± 70 N·m (391 ± 52 lb ft). Tighten two bearing cap bolts (57) to a torque of 900 ± 100 N·m (664 ± 74 lb ft).
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    Illustration 34	g00511386

45. Rotate the differential housing by 90 degrees. Install lower bearing race (11) onto the differential assembly with four Torx head screws (12).
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    Illustration 35	g00511378

46. Install bearing (10) onto the differential assembly. Lubricate the bearing assembly with clean oil.
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    Illustration 36	g00511131

47. Install hub (9) onto the differential assembly.

    Note: Three coil springs are loosely attached to hub (9). The coil springs do not need to be removed. The coil springs should be inspected for damage. Replace all three of the coil springs if any of the springs are damaged.

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    Illustration 37	g00511109

48. Install gear (8) onto the differential assembly.
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    Illustration 38	g00511092

49. Install discs and plates (7) onto the differential assembly. Maintain the order of the disc and the plates.

    Note: Apply clean oil to the discs and plates whenever new discs and plates are being installed.

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    Illustration 39	g00511036

50. Install bearing race (6) onto the differential assembly.
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    Illustration 40	g00511032

51. Lubricate bearing (5) with specified lubricant. Install bearing (5) onto the differential assembly.
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    Illustration 41	g00520922

52. Lubricate the O-rings for the piston with 1U-6395 O-Ring Assembly Compound before you install the O-rings. Install O-ring (50) onto piston (52). Install O-ring (51) onto piston (52).
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    Illustration 42	g00520932

53. Lubricate the piston and the piston housing with clean oil before you install the piston. Install piston (52) into piston housing (4).
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    Illustration 43	g00520964

54. Install three sets of bolts, washers, and spacers (53) which hold the piston in piston housing (4).
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    Illustration 44	g00511027

55. Install piston housing (4). Install four bolts (3) that hold the piston housing in place. Tighten the bolts to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
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    Illustration 45	g00510943

56. Rotate the differential assembly until the yoke is in an up right position.

57. Install the external fitting for differential lock (1) into differential assembly (2). Lubricate the O-rings with 1U-6395 O-Ring Assembly Compound before installing.

58. Install Tooling (C), a lifting strap and the hoist.

59. Remove differential assembly (2) from Tooling (A).

End By:

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