D400E Series II Articulated Truck Power Train Caterpillar

Assembly Procedure

1. Cleanliness is an important factor. Before assembly, clean all parts thoroughly 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. 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 1	g02244737

2. If a new gear (2) or a new differential housing (9) is required the dowel holes (X) will need to be reamed to the proper dimension. Bolt gear (2) to differential housing (9). Tighten the bolts to a torque of 120 ± 20 N·m (89 ± 15 lb ft). Use the transfer gear as a guide in order to ream the holes to a dimension of 12.69 ± 0.20 mm (0.500 ± 0.008 inch). Apply location marks to the components. Disassemble the gear from the differential housing.
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   Illustration 2	g00576671

3. Install shafts (16) and (22) to differential housing (9) and in the holes of the shaft's origin. The hole location of the shafts was noted during the disassembly procedure. Install roll pins (29) that secure shafts (16) and (22) in differential housing (9).

4. Install three dowels (30) to differential housing (9).
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   Illustration 3	g00576669

5. Install thrust washer (28) to differential housing (9).
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   Illustration 4	g00576668

6. Install sun gear (27) to differential housing (9).
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   Illustration 5	g00576667

7. Install sun gear (25) and thrust washer (26) to differential housing (9).
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   Illustration 6	g00576664

8. Install a thrust washer (24) to each of three planetary gear shafts (22). Install the thrust washers to the shafts of origin. The location of the thrust washers was noted during the disassembly procedure.
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   Illustration 7	g00576662

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   Illustration 8	g00576666

9. Install planetary gear (21), two caged bearings (19), and spacer (20) to each of three shafts (22). The components from each gear shaft should be installed to the shaft of origin. The location was noted with identification marks (23) during the disassembly procedure.
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   Illustration 9	g00576660

10. Install a thrust washer (18) to each of three planetary gear shafts (16). The components from each gear shaft should be installed to the shaft of origin. The location was noted with identification marks during the disassembly procedure.
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    Illustration 10	g00576658

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    Illustration 11	g00576659

11. Install planetary gear (13), two caged bearings (14), and spacer (15) to each of three shafts (16).
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    Illustration 12	g00580891

12. Install thrust discs (12) on planetary gear shafts (16) and (22). Each disc should be installed to the planetary gear shaft of origin.
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    Illustration 13	g00576654

13. Raise the temperature of roller bearing (8). Install roller bearing (8) to spider (7) until the bearing is seated.

14. Apply Tooling (A) to the mating faces of spider (7) and differential housing (9). Do not allow Tooling (A) to contact other components.

15. Position spider (7) and roller bearing (8) to differential housing (9). Position the spider to the original orientation to the housing. The orientation was noted during the disassembly procedure.

16. Install bolts (6) and the washers that secure spider (7) to differential housing (9). Tighten the bolts to a torque of 430 ± 60 N·m (317 ± 44 lb ft).

17. Turn the differential housing onto the side of the housing.
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    Illustration 14	g00576608

    Note: Dowel pins (5) must be installed below the face or flush with the face of transfer gear (2).

18. Apply Tooling (A) to the mating faces of transfer gear (2) and differential assembly (1). Do not allow Tooling (A) to contact other components. Install transfer gear (2) to differential assembly (1). Install four dowel pins (5) in transfer gear (2) and in differential assembly (1). Install bolts (3) that secure transfer gear (2) to differential housing (1). Tighten the bolts to a torque of 120 ± 20 N·m (89 ± 15 lb ft).

End By:

1. Install the interaxle differential assembly. See Disassembly and Assembly, RENR1511, "Interaxle Differential - Install".