D5M Track-Type TractorPower Train Caterpillar

Assembly Procedure

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Illustration 1	g00561159

1. Install rings (1) and (2) on piston (3). Install the rings with the lip of the rings, as shown.

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Illustration 2	g00561160

2. Install piston (3) in housing (4) .

3. Install bearing (6) on housing (4). The notch in the inner race of the bearing must be facing upward. Install snap ring (5) by using Tooling (B) .

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Illustration 3	g00561161

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Illustration 4	g00561162

4. Install bearings (7) and (10) in gear (11) .

5. Put gear (11), disc (8), and disc (9) into position in carrier assembly (14). Install shaft (13) .

Note: The rubber in pins (12) must not be damaged. If the rubber in the pins is damaged, replace the pins.

6. Align the hole in shaft (13) with the hole in the carrier and install pin (12). Install the pins until the end of the pin is even with the surface of the carrier assembly.

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Illustration 5	g00561163

7. If bearing (15) was removed from the carrier assembly, use a press and Tooling (C) and install the bearing in carrier assembly (14). The inside diameter of the bearing must be 38.139 ± 0.061 mm (1.5015 ± .0024 inch) after installation.

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Illustration 6	g00561184

8. Install ring (16) on carrier assembly (14) .

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Illustration 7	g00561186

9. Put carrier assembly (14) into position in housing (4). Install snap ring (17) by using Tooling (D) .

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Illustration 8	g00561187

10. Install bearing (21) and shaft (18) .

11. Install snap ring (20) that holds the bearing in place by using Tooling (D) .

12. Install ring (19) on shaft (18) .

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Illustration 9	g00561190

13. Put shaft (18) into position in housing (4) .

14. Use Tooling (E) to install snap ring (22) in order to hold the shaft and the bearing in position.

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Illustration 10	g00561191

15. Put housing (4) into position on the dowels in rear cover assembly (23) .

16. Align gear (24) with the carrier assembly and install the gear.

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Illustration 11	g00561244

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Illustration 12	g00561245

17. Install bearing (26) in gear (27) .

18. Put gear (27), disc (25), and disc (28) into position in carrier assembly (30). Install shaft (29) .

Note: The rubber in pins (31) must not be damaged. If the rubber in the pins is damaged, replace the pins.

19. Align the hole in shaft (29) with the hole in the carrier assembly and install pin (31). Install the pin until the end of the pin is even with the surface of the carrier assembly.

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Illustration 13	g00561249

20. Put gear assembly (33) into position on shaft (32). Install dowel (34) in order to hold the gear assembly in place.

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Illustration 14	g00677233

21. Align the notch in the inner race of bearing (37) with the dowel in gear assembly (33). Install the bearing on the gear.

22. Put gear (35) into position on the gear assembly and install snap ring (36) by using Tooling (D) .

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Illustration 15	g00677237

23. Put the ring that holds carrier assembly (30) into position in gear (38) in the groove of the carrier assembly.

24. Compress the ring and install carrier assembly (30) in gear (38) .

25. Put shaft (32) into position in carrier assembly (30), as shown.

26. Install plate (39) .

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Illustration 16	g00561258

27. Align gear (38) with the gears in the carrier. Install gear (38), carrier assembly (30), and shaft (32) as an assembly.

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Illustration 17	g00561263

Note: Install the first plate of plates (43). Align the small hole in the large tabs so that the hole is aligned with the holes for rods (40) in housing (4). Install the remaining plates. Align the large hole in the small tabs so that the hole is aligned with the large hole in the large tabs of the first plate.

28. Start with a plate and install five plates (43) and five discs (41). Alternate the plates and the discs.

29. Put rods (40) and springs (42) into position in housing (4), as shown.

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Illustration 18	g00677245

30. Put plate (44) into position on housing (4), as shown.

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Illustration 19	g00677249

Note: Align the four bottom plates (46) with the four top plates (43). The top plate (46) must be aligned with the bottom plate of plates (43) .

31. Start with a disc. Install five discs (45) and five plates (46). Alternate the discs and plates.

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Illustration 20	g00677265

32. Install rings (47) and (49) on pistons (48). Install the rings with the lip of the rings, as shown. Put clean oil on the rings.

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Illustration 21	g00677410

33. Install pistons (48) in each side of housing assembly (50) .

34. Put housing assembly (50) into position on the plate.

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Illustration 22	g00677405

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Illustration 23	g00677394

35. Install bearing (54) in gear (55) .

36. Put gear (55), disc (51), and disc (52) into position in carrier (57). Install shaft (53) .

Note: The rubber in pins (56) must not be damaged. If the rubber in the pins is damaged, replace the pins.

37. Align the hole in shaft (53) with the hole in the carrier and install pin (56). Install the pin until the end of the pin is even with the surface of the carrier.

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Illustration 24	g00677386

38. Install the ring that holds carrier (57) and gear (58) together in the groove of the carrier.

39. Compress the ring and install carrier (57) in gear (58). The ring must go in the groove of the gear.

40. Install bearing (59) in carrier (57). The notch in the inner race of the bearing must be facing upward, as shown.

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Illustration 25	g00677373

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Illustration 26	g00677365

41. Use Tooling (C) and install bearings (61) and (62) in shaft assembly (60). Install bearing (61) 10.0 ± 0.5 mm (0.4 ± 0.02 inch) below the end of the shaft. The inside diameter of bearing (61) must be 41.161 ± 0.039 mm (1.62 ± .0015 inch) after installation. Install bearing (62) 21.4 ± 0.5 mm (0.84 ± 0.02 inch) below the end of the shaft. The inside diameter of the bearing must be 41.161 ± 0.039 mm (1.62 ± .0015 inch) after installation.

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Illustration 27	g00677348

42. Align the dowel in shaft (60) with the notch in bearing (59) and install the shaft in the bearing.

43. Put plate (63) in the gear and install pin (64) .

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Illustration 28	g00677339

44. Put gear (66) into position on shaft assembly (60). Install snap ring (65) by using Tooling (D) .

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Illustration 29	g00677332

45. Install gear (67) over shaft assembly (60) .

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Illustration 30	g00677322

46. Put hub (69) into position on the shaft assembly and install snap ring (68) by using Tooling (D) .

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Illustration 31	g00677317

47. Install shaft assembly (60), carrier (57), and gear (58) on the planetary group as an assembly.

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Illustration 32	g00677313

Note: The first plate of plates (72) must be installed so that the small hole in the large tabs is aligned with rods (40). The remaining plates must be installed with the large hole in the small tabs and aligned with the large hole in the large tabs of the first plate.

48. Start with a plate. Install four plates (72) and four discs (70). Alternate the plates and the discs.

49. Install springs (71) on rods (40) .

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Illustration 33	g00677311

50. Install plate (73) on housing assembly (50) .

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Illustration 34	g00677305

51. Install plate (74) and ring (75) in gear (76) .

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Illustration 35	g00677302

52. Put gear (76) into position on the planetary group.

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Illustration 36	g00677298

53. Start with a disc. Install five discs (78) and four plates (77) in gear (76). Alternate the discs and the plates.

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Illustration 37	g00677285

54. If necessary, install pin (80) and dowel (81) in housing (79) .

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Illustration 38	g00561421

55. Put coupling (82) into position in housing assembly (79) .

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Illustration 39	g00561425

56. Install two seals (83) and ring (84) on piston (85). Install ring (84) with the lip of the ring, as shown. Put clean oil on the seals and the ring.

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Illustration 40	g00561428

57. Put piston (85) and spring (87) into position in housing assembly (79) .

58. Put spacer (86) into position on the spring.

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Illustration 41	g00561429

59. Use a press and Tooling (E) in order to compress the spring. Install snap ring (88) by using Tooling (D) .

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Illustration 42	g00561430

60. Put housing assembly (79) into position in gear (76) .

61. Use Tooling (F) and install ring (89) in order to hold the housing assembly in place.

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Illustration 43	g00677280
Prepare New Seal Rings for Installation by Using This Method.

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Illustration 44	g00677279
Do Not Use This Method to Make New Seal Rings Ready for Installation.

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Illustration 45	g00561432

Note: Illustrations 44 and 45 are for seals that are not made of metal.

62. Install two rings (90) in the grooves of the carrier.

Note: The two bottom plates (92) must be aligned with the three top plates (72). The top plate of plates (92) must be aligned with the bottom plate of plates (72) .

63. Start with a disc. Install three discs (91) and three plates (92). Alternate the plates and discs.

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Illustration 46	g00677276

64. Install rings (93) and (95) on piston (94). Install the rings with the lip of the rings, as shown. Put clean oil on the rings.

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Illustration 47	g00561436

65. Install the piston in housing assembly (96). Put the housing assembly into position on plate (73) .

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Illustration 48	g00561437

66. Install six bolts (98) that hold the planetary group to the rear cover assembly.

67. Align the notch in the inner race of bearing (99) with the dowel in the housing assembly and install the bearing.

68. Install ring (97) that holds the bearing in place.

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Illustration 49	g00561438

69. Fasten a hoist and two 8 mm forged eyebolts to housing assembly (79) .

70. Support the weight of the housing assembly by using the hoist. Install snap ring (100) by using Tooling (D) .

71. Install the two magnetic sensors (not shown) on the bevel gear case. Maintain a 0.89 mm (0.035 inch) gap between the magnetic sensor and the gear tooth.

End By:

1. Install the transmission hydraulic control valves. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Install" for the machine that is being serviced.
2. Connect the transmission and the bevel gears. Refer to Disassembly and Assembly, "Transmission and Bevel Gears - Install" for the machine that is being serviced.