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

Installation Procedure

Note: Cleanliness is an important factor. Before the installation 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. Check all of the O-ring seals and the components for wear or damage. Replace the components, if necessary.

2. Lubricate all of the O-ring seals lightly with the lubricant that is being sealed.
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   Illustration 1	g00568837

3. Install Tool (B) to planetary transmission and transfer gear (2). Attach Tool (B) to a suitable lifting device and a hoist.

4. Use Tool (B) and the hoist in order to position planetary transmission and transfer gear (2) for installation to the differential carrier assembly. The weight of planetary transmission and transfer gear (2) is 2313 kg (5100 lb).

5. Use 24 bolts (22) and the hard washers in order to install planetary transmission and transfer gear (2) and the O-ring seal to the differential carrier assembly. Tighten 24 bolts (22) to a torque of 430 ± 60 N·m (317.15 ± 44.25 lb ft).

6. Remove Tool (B) from planetary transmission and transfer gear (2).
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   Illustration 2	g00568835

7. Connect hose assembly (21).

8. Connect hose assembly (20).
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   Illustration 3	g00568833

9. Connect hose assembly (19) to the magnetic screen housing.
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   Illustration 4	g00568770

10. Use Tool (A) (not shown) in order to connect wire harness (17) to the transmission speed sensor at the electrical connection.

11. Install lockwire (18) into the electrical connector of wire harness (17).

    Note: Install the lockwire in the next endbell hole in the clockwise direction.

12. Install bolt (16), the washer and the clip to the transfer case assembly. Tighten bolt (16) to a torque of 135 ± 20 N·m (100 ± 15 lb ft).
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    Illustration 5	g00568769

13. Use two bolts (15), the washers, and the two grommets in order to install guard (14) to the speed sensor housing.
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    Illustration 6	g00567637

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    Illustration 7	g00567635

14. Use bolt (13) in order to install clip (9).

15. Connect wire harness (11) at the three electrical connections, as shown.
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    Illustration 8	g00567593

16. Use Tool (A) (not shown) in order to connect wire harness (11) to the transmission position sensor at the electrical connection.

17. Install lockwire (10) into the electrical connection of wire harness (11).

    Note: Install the lockwire in the next endbell hole in the clockwise direction.

18. Connect hose assembly (12) and two clips (9), as shown.

19. Connect hose assembly (8).
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    Illustration 9	g00567592

20. Connect hose assembly (7).

21. Connect hose assembly (6).
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    Illustration 10	g00567587

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    Illustration 11	g00567583

22. Attach a suitable lifting sling around drive shaft (5). Attach the lifting sling to a hoist.

    Note: Attach the lifting sling to the center point of drive shaft (5). This will help to balance drive shaft (5).

23. Use the hoist and the lifting sling in order to position drive shaft (5) for installation.

24. Use a suitable pry bar in order to extend drive shaft (5). Use four new bolts (4) in order to connect drive shaft (5) to the yoke of planetary transmission and transfer gear (2). Tighten four bolts (4) to a torque of 550 ± 20 N·m (405.7 ± 14.8 lb ft).

25. Remove the lifting sling from drive shaft (5).
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    Illustration 12	g00567576

26. Position guard assembly (1) onto the frame assembly. Use five bolts (3) and the hard washers in order to install guard assembly (1) to the frame assembly.

27. Fill the differential and final drive with hydraulic oil to the correct level. Refer to Operation and Maintenance Manual, SEBU7173, "Differential and Final Drive Oil - Change" for the correct procedure.

28. Fill the transmission system with hydraulic oil to the correct level. Refer to Operation and Maintenance Manual, SEBU7173, " Transmission Tank Oil - Change" for the correct procedure.

End By:

1. Remove the retaining cable. Refer to Disassembly and Assembly, SENR1500, "Body Retaining Cable - Remove and Install".

2. Remove the wheel chocks. Refer to Disassembly and Assembly, SENR1500, "Wheel Chocks (Front and Rear) - Remove and Install".