Assembly procedure
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Table 1
Required Tools     |
Tool     |
Part Number     |
Part Description     |
Qty     |
A     |
1P-2420     |
Transmission Repair Stand     |
1     |
B     |
138-7575     |
Link Bracket     |
5     |
C     |
140-7642     |
Duo-Cone Seal Installer As     |
1     |
F     |
1P-1859     |
Retaining Ring Pliers     |
1     |
G     |
138-7576     |
Link Bracket     |
2     |
H     |
5P-3931     |
Anti-Seize Compound     |
1     |
J     |
9S-3263     |
Thread Lock Compound     |
1     |
K     |
1U-8846     |
Gasket Sealant     |
1     |
- Make sure that all parts of the final drive are thoroughly clean and free of dirt and debris prior to assembly.
Note: Check the condition of all the O-ring seals that are used in the final drive. If any of the seals are worn or damaged, use new parts for replacement.
- Reassemble the final drive on Tooling (A) .
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Illustration 1 | g00599211 |
- Apply Tooling (H) to the surfaces that contact the bearing cones. Install the bearing cone with a press. Raise the temperature of bearing (50) and install bearing (50) .
- Apply Tooling (H) to the surfaces that contact pins (49) . Install pins (49) .
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Illustration 2 | g00599224 |
- Apply Tooling (H) to the surfaces that contact bearing cups (48) and (47) . Install bearing cups (48) and (47) .
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Illustration 3 | g00596986 |
- Install bearing (45) and the bearing cone.
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Illustration 4 | g01035739 |
- Attach Tooling (B) and a suitable lifting device to main housing (39) . Install the main housing on motor housing (44) , as shown.
- Use the following procedure to determine the bearing preload and the correct number of shims.
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Illustration 5 | g00603328 |
- Use a depth micrometer in order to measure the step length of the coupling gear (42) . Take measurements at several different locations around the gear. Compute the average of the measured dimensions and record the number. Call this dimension (X) .
- Use a suitable press and a spacer in order to apply a load of 10000 kg (22046 lb) on the bearings.
- Rotate the main housing in order to seat the bearing.
- Reduce the load on the bearings to 3700 ± 370 kg (8157 ± 815 lb).
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Illustration 6 | g00603604 |
- Maintain the load on the bearings. Use a depth micrometer and measure the distance between the top face of motor housing and the bearing cone, as shown. Take this measurement in several locations around the bearing. Compute the average of the measured dimensions and record the number. Call this dimension (Y) .
- Determine the correct thickness of the shim pack that will be installed between the bearing cone and the coupling gear. The shim pack thickness is equal to dimension (Y) minus dimension (X) . Tolerance for the shim pack is 0.1 mm (0.003 inch).
Note: If two shims are required, install the thinner shim next to the coupling gear when the coupling gear is installed.
- Attach Tooling (B) and a suitable lifting device in order to remove the main housing from the motor housing.
Note: Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
Note: The rubber seals and all surfaces that contact the seals must be clean and dry. After installation of the seals, apply clean SAE 30 oil on the contact surfaces of the metal seals.
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Illustration 7 | g00600071 |
- Use Tooling (C) to install Duo-Cone seal (46) in the main housing.
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Illustration 8 | g00600087 |
- Use Tooling (C) to install Duo-Cone seal (51) in the motor housing.
Note: Make sure that the Duo-Cone seals are not scratched or damaged during the assembly of the main housing or during the assembly of the motor housing. After installation of the main housing on the motor housing, there will be a small gap between the components. The gap is caused by the Duo-Cone seals. The gap will be eliminated during installation of the gear.
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Illustration 9 | g00596986 |
- Install bearing (45) and the bearing cone.
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Illustration 10 | g01035739 |
- Attach Tooling (B) and a suitable lifting device to main housing (39) . Position main housing (39) on motor housing (44) . Make sure that the Duo-Cone seals are not scratched or damaged during installation.
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Illustration 11 | g00596927 |
- Place shims (43) in the correct position on the motor housing. If two shims were required, put the thinner shim in contact with coupling gear (42) . Make sure that all of the holes in the components are in alignment with each other.
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Illustration 12 | g00596901 |
- Put coupling gear (42) in the original position on the motor housing.
- Apply Tooling (J) on the threads of bolts (41) . Install the bolts to secure coupling gear (42) in place. Tighten bolts (41) evenly and tighten the bolts in diagonally opposite pairs. Tighten bolts to a torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
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Illustration 13 | g00596864 |
- Install O-ring seal (40) in the main housing.
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Illustration 14 | g01035734 |
- Thoroughly clean the mating surface of main housing (39) that contacts ring gear (38) . Apply a bead of Tooling (K) on the mating surface of ring gear (38) . Use Tooling (B) and a suitable lifting device. Place the ring gear in position on the main housing. Make sure that the alignment mark on the main housing and the ring gear line up with each other. It may be necessary to use a soft faced hammer to seat the ring gear on the main housing.
- Assemble carrier assembly (29) , as follows:
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Illustration 15 | g00596823 |
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Illustration 16 | g00603856 |
- Apply clean SAE 30 oil on bearings (34) and (36) . Install bearings (34) and (36) in planetary gear (35) .
- Install thrust washers (33) and (37) on each side of the planetary gear.
- Install the planetary gear and thrust washers in carrier assembly (29) .
- Install planetary shaft (30) in carrier (29) and through planetary gear assembly (32) . Make sure that the spring pin hole in the planetary shaft is in alignment with the spring pin hole in the carrier.
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Illustration 17 | g00513451 |
- Install spring pin (31) in the carrier and into the planetary shaft. Make sure that the spring pin hole in the planetary shaft is in alignment with the spring pin hole in the carrier.
- Orient the split in the spring pin (31) horizontally to the carrier. Align the split in the spring pin to the left or to the right. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (0.06 inch) to 3.00 mm (0.118 inch) from the outside diameter of the spring pin hole.
- Repeat Steps 19.a through 19.f in order to install the remaining planetary gears in carrier (29) .
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Illustration 18 | g01035740 |
- Attach Tooling (B) and a suitable lifting device to carrier assembly (29) . Put the carrier assembly in position in the ring gear. It may be necessary to move the carrier assembly back and forth during installation in order to ensure that all gears engage properly.
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Illustration 19 | g00603929 |
- Install spacer (28) on carrier assembly (29) .
- Assemble carrier assembly (21) , as follows:
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Illustration 20 | g00596485 |
- Apply clean SAE 30 oil on bearing (23) . Install bearing (23) in planetary gear (24) .
- Install thrust washers (22) and (25) on each side of the planetary gear.
- Install the thrust washers and the planetary gear in the carrier assembly (21) .
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Illustration 21 | g00596446 |
- Install planetary shaft (20) in carrier (21) and through planetary gear assembly (24) . Make sure that the spring pin hole in the carrier is in alignment with the spring pin hole in the planetary shaft.
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Illustration 22 | g00596442 |
- Make sure that the spring pin (19) in the planetary shaft is in alignment with the spring pin hole in the carrier.
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Illustration 23 | g00513451 |
- Orient the split in the spring pin (19) horizontally to the carrier. Align the split in the spring pin to the left or to the right. Make a stake mark on each side of the spring pin hole in the carrier. This will prevent the spring pin from falling out of the spring pin hole. Each stake mark should be approximately 1.5 mm (0.06 inch) to 3.00 mm (0.118 inch) from the outside diameter of the spring pin hole.
- Repeat Steps 22.a through 22.f in order to install the remaining two planetary gears in carrier (18) .
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Illustration 24 | g01035731 |
- Attach Tooling (B) and a suitable lifting device to carrier assembly (18) . Position carrier assembly (18) in ring gear (38) . Move carrier assembly (18) back and forth during the installation in order to ensure that all gears engage properly.
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Illustration 25 | g00596342 |
- Install spacer (17) .
- Assemble carrier assembly (8) , as follows:
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Illustration 26 | g00596337 |
- Install washers (16) and gear (15) . Use suitable Tooling to install ring (14) .
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Illustration 27 | g00596273 |
- Install bearings (12) and spacer (13) .
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Illustration 28 | g00596269 |
- Install gears (11) .
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Illustration 29 | g00596242 |
- Install washers (10) . Use Tooling (F) in order to install retaining ring (9) .
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Illustration 30 | g00596082 |
- Use two people to install carrier assembly (8) . The weight of the carrier assembly (8) is approximately 24 kg (53 lb). Install sun gear (7) .
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Illustration 31 | g00596018 |
- Install ring gear (6) into the cover. Tighten bolts (5) to a torque of 100 ± 20 N·m (74 ± 15 lb ft). Install spacer (4) .
The weight of the cover is approximately 65 kg (143 lb).
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Illustration 32 | g00604398 |
- Attach Tooling (G) and a suitable lifting device to cover (2) . Install bolts (3) and the washers. Tighten bolts (3) to a torque of 1600 ± 200 N·m (1180 ± 148 lb ft).
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Illustration 33 | g00596007 |
- Install socket head bolts (1) .
End By:
Install the final drives and the travel motors. Refer to Disassembly and Assembly, "Final Drive - Install".