980G Wheel Loader Power Train Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, 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. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

Note: Use the correct method to make the new rings ready for installation. Place your hands on each end of the ring and expand the ends by each other. Keep the ring in a circular shape in order to ensure an even bend fully around the ring. The notches in the ends of the rings must contact each other. The ring will damage the edge of the bore if the ring is not installed correctly. The notches must be fully engaged.

Illustration 1	g00397059
Correct method for compressing the rings

Illustration 2	g00397061
The ends of the ring must contact the inner notches (bottom half of the above illustration).

Illustration 3	g00397157
Do not use this method to make new rings ready for installation.

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Illustration 4	g01087413

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Illustration 5	g00832553

1. Use Tooling (G) to install bearing (134) in the No. 1 clutch housing. Install the bearing with the notch in the UPWARD position. Use Tooling (J) to install retaining ring (133) in the groove of the No. 1 clutch housing.
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   Illustration 6	g00832555

2. Install seals (131) and (132) on clutch piston (130) so that the oil grooves are facing toward the inside of the clutch housing. Apply clean transmission oil on the seal rings.
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   Illustration 7	g00832558

3. Install piston (130) in the No. 1 clutch housing.
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   Illustration 8	g00832561

4. Install gear (129) in the No. 1 clutch housing.
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   Illustration 9	g01087471

5. Use Tooling (H) to install bearing (128) in the end of the shaft assembly.
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   Illustration 10	g01087475

6. Raise the temperature of seal carrier (127) to a maximum temperature of 149 °C (300 °F). Install seal carrier (127) on the shaft assembly.
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   Illustration 11	g00832640

7. Install bearing (126) on the shaft assembly. Use Tooling (J) to install retaining ring (125) that holds bearing (126) in position.
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   Illustration 12	g00832651

8. Install shaft assembly (124) in shaft assembly (123).
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   Illustration 13	g00832673

9. Install spiral lockring (122) that holds the shafts in position.
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   Illustration 14	g01087342

10. Put the shaft assembly in position on suitable blocks, as shown. Install gear (119) on the shaft assembly.

11. Install seals (120) and (121) on the seal carrier. Put a small amount of SAE 30 oil on the seals.
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    Illustration 15	g01087333

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    Illustration 16	g01087505

12. Install bearings (111) and (115) (not shown) in gears (116) and (112).

13. Install thrust discs (114), (117), (110), and (113) on each side of the gears. Put gears (112) and (116) in position in the carrier. Install shaft (118).
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    Illustration 17	g01087501

14. Use a hammer and a punch to install spring pin (109) that holds shaft (118) in the carrier assembly. Make sure that spring pin (109) is flush with the counterbore in the carrier.

15. Repeat Steps 12 through 14 for the installation of the remaining gears.
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    Illustration 18	g00832693

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    Illustration 19	g01087512

16. Use Tooling (G) to install bearing (108) in the carrier. Install bearing (108) with the notch in the UPWARD position. Install spiral lockring (107) in the carrier.

17. Install seal rings (108A) on the carrier. Apply clean transmission oil on seal rings (108A).
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    Illustration 20	g01087516

18. Install retainer ring (106A) in the carrier. Compress retainer ring (106A) in order to install gear (106).
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    Illustration 21	g00832696

19. Use two people to install carrier assembly (105) on the shaft assembly. Make sure that the notch in the carrier bearing is in alignment with the dowel in the shaft assembly.
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    Illustration 22	g00832704

20. Install gear (104) and spacer (103) on the shaft assembly.
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    Illustration 23	g01087259

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    Illustration 24	g01087526

21. Install bearings (100) in the gears.

22. Place thrust discs (98) and (101) on each side of the gears.

23. Put gears (99) in position in the carrier. Install shafts (102).
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    Illustration 25	g01087770

24. Use a hammer and a punch to install the spring pin (97) that holds planetary shaft (102) in the carrier assembly. Make sure that spring pin (97) is flush with the counterbore in the carrier.

25. Repeat Steps 21 through 24 for the installation of the remaining gears.
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    Illustration 26	g01087774

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    Illustration 27	g01087257

26. Use Tooling (G) to install bearing (94) in the carrier. Install bearing with the notch in the DOWNWARD position. Install seals (95) and (96) and spiral lockring (93).
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    Illustration 28	g01087792

27. Install carrier assembly (92) on the shaft assembly (91). Align the notch in the bearing with the dowel in the shaft.

28. Use Tooling (E) to install retaining ring (90) (not shown) on the shaft assembly.
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    Illustration 29	g01087782

29. Put the No. 1 clutch housing in position on wood blocks, as shown. Install Tooling (C) in the shaft assembly (89), as shown. Install shaft assembly and carriers in the No. 1 clutch housing. Make sure that the notch in the bearing is in alignment with the dowel in the carrier assembly.

30. Use Tooling (E) to install the retaining ring (not shown) on the bottom of the carrier assembly.
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    Illustration 30	g00833028

31. Start with a friction disc and install friction discs (87) and clutch plates (88) in the housing.
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    Illustration 31	g01087802

32. Install plate assembly (86) on the housing. Install gear assembly (85).
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    Illustration 32	g00833034

33. Start with a friction disc and install friction discs (83) and clutch plates (84).
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    Illustration 33	g00833067

34. Apply clean transmission oil on seal rings (82) and install seals (81) on the piston.
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    Illustration 34	g00833069

35. Install piston (80) in the No. 2 clutch housing.
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    Illustration 35	g01087229

36. Install springs (78).

37. Use Tooling (D) to hold the piston in No. 2 clutch housing (77). Attach Tooling (B) and a suitable lifting device to No. 2 clutch housing (77). Install No. 2 clutch housing (77). Install bolts (76) that hold the No. 1 housing and No. 2 clutch housing (77) together. Install dowels (79).
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    Illustration 36	g01087225

38. Install gear (75) on the shaft assembly.
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    Illustration 37	g01087221

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    Illustration 38	g01087829

39. Install bearings (72) in the gears.

40. Install thrust discs (70) and (73) on each side of the gears. Put gears (71) in position in the carrier. Install shafts (74).

41. Repeat Steps 38 through 40 for the installation of the remaining gears.
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    Illustration 39	g01087846

42. Use a hammer and a punch to install spring pin (69 ) that holds planetary shaft (74) in the carrier assembly. Make sure that spring pin (69) is flush with the counterbore in the carrier assembly.
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    Illustration 40	g01087849

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    Illustration 41	g00833324

43. Use Tooling (G) to install the bearing (68) in the carrier. Install bearing with the notch in the UPWARD position.

44. Install the spiral lockring (67) in the carrier.
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    Illustration 42	g01087856

45. Put retaining ring (66A) in position on the carrier. Compress the retaining ring in order to install the gear (66).
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    Illustration 43	g01087392

46. Install the carrier on hub (65). Make sure that the notch in the bearing is in alignment with the dowel on hub (65). Use Tooling (E) to install retaining ring (64) on hub (65).
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    Illustration 44	g01088079

47. Install Tooling (B) and a suitable lifting device on carrier (63). The weight of carrier (63) is approximately 26 kg (58 lb). Install carrier (63). Use Tooling (E) to install retaining ring (62) on the shaft assembly.
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    Illustration 45	g01087877

48. Install dowels (38) in the housing.

49. Start with a friction disc and install friction discs (60) and clutch plates (61).
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    Illustration 46	g00833462

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    Illustration 47	g01089975

50. Install seals (58) and (59) on piston (57). Apply clean transmission oil to the seals. Install piston (57) in the housing.
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    Illustration 48	g01088082

51. Install springs (56).

52. Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to No. 3 clutch housing (55). The weight of No. 3 clutch housing (55) is approximately 38 kg (85 lb). Install No. 3 clutch housing (55).
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    Illustration 49	g01087933

53. Install gear (45A) on the carrier.
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    Illustration 50	g01087935

54. Put housing assembly (48) in position on the gear.
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    Illustration 51	g01087941

55. Start with a friction disc and install five friction discs (46) and four clutch plates (46A) in housing (48).
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    Illustration 52	g01087968

56. If the ring carrier was removed from the housing assembly, heat a new ring carrier to a maximum temperature of 149 °C (300 °F). Install ring carrier (42) on the housing assembly. Install pin (43) in the housing assembly.
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    Illustration 53	g01087969

57. Install seal rings (41). Apply clean transmission oil to seal rings (41).
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    Illustration 54	g01087973

58. Install seals (53) and (54) on piston (52). Apply clean transmission oil to seals (53) and (54).

59. Install piston (52) in housing assembly (54A).
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    Illustration 55	g01087980

60. Install springs (51):

    1. Install the first spring (51) with the outside diameter in contact with the housing assembly.

    2. Install the next two springs (51) with the outside diameter of the springs in contact with each other, as shown.

61. Install plate (49) on the springs. Make sure that the holes in the plate, and the springs are in alignment with the holes in the housing assembly.
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    Illustration 56	g01088000

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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.

62. Install Tooling (K) in the housing assembly, as shown. Compress the springs until spiral lockring (50) can be installed on the housing assembly. Release the pressure on the springs and remove Tooling (K).
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    Illustration 57	g01087995

63. Install housing assembly (47) on the No. 5 clutch housing (40). Install bolts (44) that secure the No. 5 clutch housing (40). Install retainer ring (39) on the shaft assembly.
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    Illustration 58	g01084546

64. Start with a friction disc and install two friction discs (37) and one clutch plate (36) over dowels (38).
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    Illustration 59	g00833601

65. Apply clean transmission oil to seals (35) and (34). Install seals (34) and (35) on the piston (33).
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    Illustration 60	g00833604

66. Install piston (33) in the No. 5 clutch housing.
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    Illustration 61	g01088089

67. Install springs (32) in the No. 4 clutch housing.

68. Use Tooling (D) to hold the piston in the No. 4 clutch housing (31). Attach Tooling (B) and a suitable lifting device to No. 4 clutch housing (31). Install No. 4 clutch housing (31).
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    Illustration 62	g00833608

69. Install bolts (30) that secure the clutch housing.
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    Illustration 63	g01088009

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    Illustration 64	g00833611

70. Use Tooling (G) to install bearing (29) in the manifold assembly. Install bearing with the notch in the DOWNWARD position.

71. Install retaining ring (28) in the manifold.
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    Illustration 65	g01088014

72. Install O-ring seal (27A) on the manifold assembly (27). Apply clean transmission oil to O-ring seal (27A).

73. Attach Tooling (B) and a suitable lifting device to the manifold. Position manifold assembly (27) on the housing. Make sure that the notch in the manifold bearing is in alignment with the dowel on the housing assembly.
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    Illustration 66	g00833623

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    Illustration 67	g00833618

74. Install O-ring seal (25) on the manifold assembly. Apply clean transmission oil to O-ring seal (25). Install bolts (26).

75. Install gear (24) on the shaft assembly. Install retaining ring (23).
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    Illustration 68	g00833652

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    Illustration 69	g01088019

76. Install bearings (19) and (21) in gears (20).

77. Install thrust discs (18) and (22) on each side of the gears (20). Put gears (20) in position in the carrier. Install planetary shafts (17). Make sure that the holes in planetary shafts (17) are in alignment with the holes in the carrier.

78. Repeat Steps 75 through 77 for the installation of the remaining gears.
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    Illustration 70	g01088020

79. Use a hammer and a punch to install spring pins (16) that hold planetary shaft (17) in the carrier assembly. Make sure that spring pins (16) are flush with the counterbore in the carrier.
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    Illustration 71	g01087364

80. Put slinger (15) in position in the carrier. Install locks (13) and bolts (14) that hold the slinger (15) in position. Bend the tabs on locks (13).
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    Illustration 72	g00833660

81. Put carrier (12) in position on the shaft assembly. Install the spacer on the carrier. Use Tooling (E) to install retaining ring (11) on the shaft assembly.
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    Illustration 73	g00833667

82. Install gear (10) on the manifold assembly.
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    Illustration 74	g01087359

83. Install dowels (9) in the manifold assembly.

84. Start with a friction disc and install three friction discs (7) and two clutch plates (8).
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    Illustration 75	g01088048

85. Install seals (6A) on the piston. Apply clean transmission oil to O-ring seals (6A).

86. Install piston (6) in the No. 6 clutch housing.
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    Illustration 76	g01087353

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    Illustration 77	g00833679

87. Install springs (4). Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to the housing. Install No. 6 clutch housing (102). Install bolts (3) that secure the planetary group.

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    Illustration 78	g01088174

89. Attach Tooling (B) and a suitable lifting device to planetary group (1). The weight of planetary group (1) is approximately 567 kg (1250 lb). Position planetary group (1) in transmission case (2). Install the two bolts that connect the transmission case to the planetary group.

End By:

1. Install the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Install" for the machine that is being serviced.

2. Connect the transmission to the torque converter. Refer to Disassembly and Assembly, "Transmission to Torque Converter - Connect" for the machine that is being serviced.