Required Tools | |||
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Tool | Part Number | Part Description | Qty |
A | 180-3032 | Jack Stand Gp | 1 |
B | 439-3939 | Link Bracket As | 4 |
E | 203-5582 | Lifting Plate | 1 |
F | FT-2769 | Table | 1 |
H | 5P-4758 | Retaining Ring Pliers As | 1 |
J | 9U-7479 | Spring Compressor | 1 |
L | 8T-5096 | Dial Indicator Gp | 1 |
M | 1U-9204 | Lever Puller Hoist | 1 |
N | 4C-8358 | Eyebolt | 1 |
Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts in cleaning fluid. Allow the parts to air dry. Do not use wiping cloths or rags to dry parts. Lint may be deposited on the parts which may cause trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Dirt and other contaminants can damage the precision component. Perform assembly procedures on a clean work surface. Keep components covered and protected at all times.
Note: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.
Note: Lubricate all seal rings and O-ring seals prior to assembly.
NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
- Assemble clutch pack (137). Refer to Steps 44 through 46.
- Install bearing cups (138). Position clutch pack (137) and install bolts (136).
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Illustration 2 g01273410 - Refer to Steps 33 through 36 for the assembly of clutch pack (135).
- Raise the temperature of bearing cone (131). Install gear (134), thrust washer (133), spacer (132), and bearing cone (131).
Note: Allow bearing cone (131) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (131) to ensure that bearing cone (131) is seated properly.
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Illustration 3 g01273984 - Reposition shaft assembly (122) in order to install clutch pack (130). Refer to Steps 33 through 36 for the assembly of clutch pack (130).
- Install gear (129), thrust washer (128), and spacer (127).
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Illustration 4 g01273334 - Raise the temperature of bearing cone (121). Install gear (126), gear (125), spacer (124), spacer (123), and bearing cone (121).
Note: Allow bearing cone (121) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (121) to ensure that bearing cone (121) is seated properly.
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Illustration 5 g01382587 - Refer to Steps 33 through 36 for the assembly of clutch pack (119).
Note: Note the location of spacer (120) when clutch pack (119) is assembled.
- Install gear (118), thrust washer (117), sun gear (116), tube (115), and thrust washer (114).
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Illustration 6 g01273268 - Refer to Step 19 for the assembly of planetary carrier (113).
- Raise the temperature of bearing cone (111). Install planetary carrier (113), spacer (112), and bearing cone (111).
Note: Allow bearing cone (111) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (111) to ensure that bearing cone (111) is seated properly.
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Illustration 7 g01274137 - Install rotor (110) and bolts (109).
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Illustration 8 g01382623 - Reposition shaft assembly (91) in order to install clutch pack (106). Refer to Steps 33 through 36 for the assembly of clutch pack (106).
- Sun gear (103) and tube (102) are assembled with a captive retaining ring (103A). Retaining ring (103A) must be compressed with suitable rods in order to assemble sun gear (103) and tube (102).
- Install gear (105) and thrust washer (104). Install retaining ring (103A), sun gear (103), tube (102), and thrust washer (101).
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Illustration 9 g01273209 - Position bearings (99), thrust discs (98), and gear (100) into the planetary housing. Install shaft (96) and pin (95). Repeat for the remaining planetary gears.
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Illustration 10 g01273177 - Raise the temperature of bearing cone (92). Install planetary carrier (94), spacer (93), and bearing cone (92).
Note: Allow bearing cone (92) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (92) to ensure that bearing cone (92) is seated properly.
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Illustration 11 g01274195 - Position shaft assembly (72).
- Refer to Steps 33 through 36 for the assembly of clutch pack (90).
- Install gear (89), thrust washer (88), spacer (87), and gear (86).
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Illustration 12 g01274191 - Raise the temperature of bearing cone (82). Install gear (85), spacer (84), spacer (83), and bearing cone (82).
Note: Allow bearing cone (82) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (82) to ensure that bearing cone (82) is seated properly.
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Illustration 13 g01274278 - Install spring pin (81).
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Illustration 14 g01274310 - Reposition shaft assembly (72).
- Refer to Steps 33 through 36 for the assembly of clutch pack (78).
- Raise the temperature of bearing cone (73). Install gear (77), thrust washer (76), spacer (75), spacer (74), and bearing cone (73).
Note: Allow bearing cone (73) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (73) to ensure that bearing cone (73) is seated properly.
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Illustration 15 g01274399 - Position shaft assembly (46).
- Install ring seals (71) onto shaft assembly (46). Install ring seals (68) and (70) onto piston (69). Install piston (69).
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Illustration 16 g01272604 - Install spring (67), seal assembly (66), and spacer (65).
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Illustration 17 g01272577 Show/hide tablePersonal 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.
- Use a suitable press and Tooling (J) to compress spring (64). Install retaining ring (63).
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Illustration 18 g01274828 - Install clutch discs and plates (62). Install clutch plate (61). Use Tooling (H) in order to install retaining ring (60). Install thrust washer (59), bearing (58) and bearing (57).
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Illustration 19 g01274797 - Raise the temperature of bearing cone (53). Install thrust washer (56), gear (55), spacer (54), and bearing cone (53).
Note: Allow bearing cone (53) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (53) to ensure that bearing cone (53) is seated properly.
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Illustration 20 g01274934 - Reposition shaft assembly (46). Raise the temperature of bearing cone (45).
- Install spacer (50), gear (49), spacer (48), spacer (47), and bearing cone (45).
Note: Allow bearing cone (45) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (45) to ensure that bearing cone (45) is seated properly.
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Illustration 21 g01272218 - Position shaft assemblies (44) together. Install Tooling (E). The weight of shaft assemblies (44) is approximately
590 kg (1300 lb) . Remove shaft assemblies (44) from Tooling (F).Show/hide tableIllustration 22 g01272065 - Install shaft assemblies (44). Remove Tooling (E).
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Illustration 23 g01271911 - Install seals (42) and (43).
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Illustration 24 g01271857 - Install dowels (39), springs (38), and piston (40) onto housing (41). Install discs and plates (37).
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Illustration 25 g01387415 Show/hide tablePersonal 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.
- Install ring gear (36) and reaction plate (35). Install bolts (34).
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Illustration 26 g01283696 - Install the O-ring seals on the back side of clutch (33). Use two people to install clutch (33). The weight of clutch (33) is approximately
25 kg (55 lb) . Install bolts (32).Show/hide tableIllustration 27 g01271784 - Reposition housing assembly (30). Attach Tooling (B) and a suitable lifting device to housing assembly (30). The weight of housing assembly (30) is approximately
431 kg (950 lb) . Position housing assembly (30) and install bolts (31).Show/hide tableIllustration 28 g01270613 Show/hide tableIllustration 29 g01375191 Show/hide tableIllustration 30 g01375198 - Use the following steps in order to determine the shim thickness:
- Lower the temperature of bearing cup (24). Install bearing cup (24) in cage assembly (23).
Note: Allow bearing cup (24) and the cage assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cup (24) to ensure that bearing cup (24) is seated properly.
- Install cage assembly (23) and bolts (22) without the shim pack.
- Install five new bolts (22) at the Locations that are shown in Illustration 30. Install bolts (22) until the bolts are finger tight. Tighten bolts (22) in sequence by 1/4 turn. Tighten each bolt evenly. Tighten the bolts until a torque of
2.3 N·m (20 lb in) is achieved at each bolt. - Rotate the shaft for a minimum of five revolutions.
- Tighten each bolt evenly. Tighten the bolts until a torque of
5.6 N·m (50 lb in) is achieved at each bolt. - Rotate the shaft for a minimum of five revolutions.
- Tighten each bolt evenly. Tighten the bolts again until a torque of
5.6 N·m (50 lb in) is achieved at each bolt. - Repeat Steps 49.g and 49.h until the specified torque no longer turns the bolts.
- Use a suitable gauge to measure the gap between the cage assembly and the rear case in 2 places that are 180 degrees apart. Record the measurements and the average of the measurements. Record the average of the measurements as Dimension (X).
- Add
0.479 mm (0.0189 inch) to Dimension (X) from Step 49.j in order to determine the total shim thickness. - Set the shims to the recommended thickness and verify the thickness with a micrometer.
Show/hide tableIllustration 31 g01375191 - Lower the temperature of bearing cup (24). Install bearing cup (24) in cage assembly (23).
- Remove bolts (22) and cage assembly (23).
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Illustration 32 g01375244 Show/hide tableIllustration 33 g01375246 - Install the shims, cage assembly (23), and bolts (22).
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Illustration 34 g01270762 - Lower the temperature of bearing cups (29). Install bearing cups (29) into cage assemblies (25), (27), and (28).
Note: Allow bearing cups (29) and the cage assemblies to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cups (29) to ensure that bearing cups (29) are seated properly.
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Illustration 35 g01375258 - Install the shims, cage assembly (25), and bolts (26). Repeat for cage assemblies (27).
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Illustration 36 g01375272 Note: It is important to rotate the shaft during the end play adjustment in order to seat the bearings properly.
- Attach Tooling (N) and a suitable lifting device to the shaft assembly. Install Tooling (L). Apply a slight lifting tension to the shaft assembly. Use Tooling (L) to check the end play of the shaft assembly. Adjust the number of shims in order to obtain an end play of
0.05 to 0.10 mm (0.002 to 0.004 inch) . - Repeat Step 55 for the remaining shafts.
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Illustration 37 g01276939 - Raise the temperature of bearing cone (19). Install retaining ring (21), gear (20), and bearing cone (19) onto shaft (18).
Note: Allow bearing cone (19) and the shaft assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cone (19) to ensure that bearing cone (19) is seated properly.
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Illustration 38 g01270506 - Attach Tooling (B) and a suitable lifting device to shaft assembly (17). The weight of shaft assembly (17) is approximately
82 kg (180 lb) . Install shaft assembly (17).Show/hide tableIllustration 39 g01382669 - Lubricate lip seal (14A) with clean transmission oil prior to assembly.
Note: Note the orientation of spacer (14) during assembly.
- Install spacer (14), lip seal (14A), yoke (15), O-ring seal (15A), retainer (16), and bolt (16A).
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Illustration 40 g01381923 - Install spacer (13A). Use two people in order to install gear (13). The weight of gear (13) is approximately
25 kg (55 lb) . Install retainer (12) and bolt (11).Show/hide tableIllustration 41 g01269759 - Install tube assembly (10).
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Illustration 42 g01269757 - Use Tooling (B) and a suitable lifting device to position cover assembly (9) on the transmission. The weight of cover assembly (9) is approximately
82 kg (180 lb) . Install bolts (8).Show/hide tableIllustration 43 g01269755 Show/hide tableIllustration 44 g01277003 - Lower the temperature of bearing cup (7) and install bearing cup (7) in cage assembly (6).
Note: Allow bearing cup (7) and the cage assembly to reach a uniform temperature.
- Use a suitable driver or a press to reset bearing cup (7) to ensure that bearing cup (7) is seated properly.
- Install the shims, cage assembly (6), and bolts (5).
- Check the end play of shaft assembly (17). Refer to Step 55.
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Illustration 45 g01382720 - Lubricate lip seal (3A) with clean transmission oil prior to assembly.
Note: Note the orientation of spacer (4) during assembly.
- Install spacer (4), lip seal (3A), yoke (3), the O-ring seal, retainer (2), and bolt (1).
- Install tube assembly (4A).
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Illustration 46 g01279522 Show/hide tableIllustration 47 g01279616 - Attach Tooling (B), Tooling (M), and a suitable lifting device to the transmission. The weight of the transmission is approximately
1588 kg (3500 lb) . Reposition the transmission and place the transmission onto suitable blocking, as shown.Show/hide tableIllustration 48 g01273481 - Install O-ring seals (142) and lip seal (143) onto carrier (141).
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Illustration 49 g01280603 Note: Discard bolts (79) and (107) and replace.
- Install the seal rings onto the seal carriers. Install seal carrier (52) and bolts (51). Install seal carriers (80) and (108). Install bolts (79) and (107). Tighten bolts (79) and (107) to a torque of
80 ± 5 N·m (60 ± 4 lb ft) .Show/hide tableIllustration 50 g01279496 - Install covers (139). Install carrier assembly (141) and bolts (140).
Illustration 1 | g01283687 |
End By:
- Install the input speed sensor. Refer to Disassembly and Assembly, "Speed Sensor - Install".