TA22 Transmission Caterpillar


Transmission - Assemble

Usage:

TA22-M4WD T4W

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
180-3032  Jack Stand Gp 
439-3939  Link Bracket As 
203-5582  Lifting Plate 
FT-2769  Table 
5P-4758  Retaining Ring Pliers As 
9U-7479  Spring Compressor 
8T-5096  Dial Indicator Gp 
1U-9204  Lever Puller Hoist 
4C-8358  Eyebolt 

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

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.




    Illustration 1g01283687

  1. Assemble clutch pack (137). Refer to Steps 44 through 46.

  2. Install bearing cups (138). Position clutch pack (137) and install bolts (136).


    Illustration 2g01273410

  3. Refer to Steps 33 through 36 for the assembly of clutch pack (135).

  4. 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.

  5. Use a suitable driver or a press to reset bearing cone (131) to ensure that bearing cone (131) is seated properly.


    Illustration 3g01273984

  6. Reposition shaft assembly (122) in order to install clutch pack (130). Refer to Steps 33 through 36 for the assembly of clutch pack (130).

  7. Install gear (129), thrust washer (128), and spacer (127).


    Illustration 4g01273334

  8. 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.

  9. Use a suitable driver or a press to reset bearing cone (121) to ensure that bearing cone (121) is seated properly.


    Illustration 5g01382587

  10. 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.

  11. Install gear (118), thrust washer (117), sun gear (116), tube (115), and thrust washer (114).


    Illustration 6g01273268

  12. Refer to Step 19 for the assembly of planetary carrier (113).

  13. 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.

  14. Use a suitable driver or a press to reset bearing cone (111) to ensure that bearing cone (111) is seated properly.


    Illustration 7g01274137

  15. Install rotor (110) and bolts (109).


    Illustration 8g01382623

  16. Reposition shaft assembly (91) in order to install clutch pack (106). Refer to Steps 33 through 36 for the assembly of clutch pack (106).

  17. 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).

  18. Install gear (105) and thrust washer (104). Install retaining ring (103A), sun gear (103), tube (102), and thrust washer (101).


    Illustration 9g01273209

  19. 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.


    Illustration 10g01273177

  20. 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.

  21. Use a suitable driver or a press to reset bearing cone (92) to ensure that bearing cone (92) is seated properly.


    Illustration 11g01274195

  22. Position shaft assembly (72).

  23. Refer to Steps 33 through 36 for the assembly of clutch pack (90).

  24. Install gear (89), thrust washer (88), spacer (87), and gear (86).


    Illustration 12g01274191

  25. 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.

  26. Use a suitable driver or a press to reset bearing cone (82) to ensure that bearing cone (82) is seated properly.


    Illustration 13g01274278

  27. Install spring pin (81).


    Illustration 14g01274310

  28. Reposition shaft assembly (72).

  29. Refer to Steps 33 through 36 for the assembly of clutch pack (78).

  30. 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.

  31. Use a suitable driver or a press to reset bearing cone (73) to ensure that bearing cone (73) is seated properly.


    Illustration 15g01274399

  32. Position shaft assembly (46).

  33. Install ring seals (71) onto shaft assembly (46). Install ring seals (68) and (70) onto piston (69). Install piston (69).


    Illustration 16g01272604

  34. Install spring (67), seal assembly (66), and spacer (65).


    Illustration 17g01272577

    ------ WARNING! ------

    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.


  35. Use a suitable press and Tooling (J) to compress spring (64). Install retaining ring (63).


    Illustration 18g01274828

  36. 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).


    Illustration 19g01274797

  37. 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.

  38. Use a suitable driver or a press to reset bearing cone (53) to ensure that bearing cone (53) is seated properly.


    Illustration 20g01274934

  39. Reposition shaft assembly (46). Raise the temperature of bearing cone (45).

  40. 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.

  41. Use a suitable driver or a press to reset bearing cone (45) to ensure that bearing cone (45) is seated properly.


    Illustration 21g01272218

  42. 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).


    Illustration 22g01272065

  43. Install shaft assemblies (44). Remove Tooling (E).


    Illustration 23g01271911

  44. Install seals (42) and (43).


    Illustration 24g01271857

  45. Install dowels (39), springs (38), and piston (40) onto housing (41). Install discs and plates (37).


    Illustration 25g01387415

    ------ WARNING! ------

    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.


  46. Install ring gear (36) and reaction plate (35). Install bolts (34).


    Illustration 26g01283696

  47. 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).


    Illustration 27g01271784

  48. 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).


    Illustration 28g01270613


    Illustration 29g01375191


    Illustration 30g01375198

  49. Use the following steps in order to determine the shim thickness:

    1. 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.

    2. Use a suitable driver or a press to reset bearing cup (24) to ensure that bearing cup (24) is seated properly.

    3. Install cage assembly (23) and bolts (22) without the shim pack.

    4. 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.

    5. Rotate the shaft for a minimum of five revolutions.

    6. Tighten each bolt evenly. Tighten the bolts until a torque of 5.6 N·m (50 lb in) is achieved at each bolt.

    7. Rotate the shaft for a minimum of five revolutions.

    8. Tighten each bolt evenly. Tighten the bolts again until a torque of 5.6 N·m (50 lb in) is achieved at each bolt.

    9. Repeat Steps 49.g and 49.h until the specified torque no longer turns the bolts.

    10. 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).

    11. Add 0.479 mm (0.0189 inch) to Dimension (X) from Step 49.j in order to determine the total shim thickness.

    12. Set the shims to the recommended thickness and verify the thickness with a micrometer.


    Illustration 31g01375191

  50. Remove bolts (22) and cage assembly (23).


    Illustration 32g01375244


    Illustration 33g01375246

  51. Install the shims, cage assembly (23), and bolts (22).


    Illustration 34g01270762

  52. 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.

  53. Use a suitable driver or a press to reset bearing cups (29) to ensure that bearing cups (29) are seated properly.


    Illustration 35g01375258

  54. Install the shims, cage assembly (25), and bolts (26). Repeat for cage assemblies (27).


    Illustration 36g01375272

    Note: It is important to rotate the shaft during the end play adjustment in order to seat the bearings properly.

  55. 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).

  56. Repeat Step 55 for the remaining shafts.


    Illustration 37g01276939

  57. 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.

  58. Use a suitable driver or a press to reset bearing cone (19) to ensure that bearing cone (19) is seated properly.


    Illustration 38g01270506

  59. 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).


    Illustration 39g01382669

  60. Lubricate lip seal (14A) with clean transmission oil prior to assembly.

    Note: Note the orientation of spacer (14) during assembly.

  61. Install spacer (14), lip seal (14A), yoke (15), O-ring seal (15A), retainer (16), and bolt (16A).


    Illustration 40g01381923

  62. 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).


    Illustration 41g01269759

  63. Install tube assembly (10).


    Illustration 42g01269757

  64. 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).


    Illustration 43g01269755


    Illustration 44g01277003

  65. 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.

  66. Use a suitable driver or a press to reset bearing cup (7) to ensure that bearing cup (7) is seated properly.

  67. Install the shims, cage assembly (6), and bolts (5).

  68. Check the end play of shaft assembly (17). Refer to Step 55.


    Illustration 45g01382720

  69. Lubricate lip seal (3A) with clean transmission oil prior to assembly.

    Note: Note the orientation of spacer (4) during assembly.

  70. Install spacer (4), lip seal (3A), yoke (3), the O-ring seal, retainer (2), and bolt (1).

  71. Install tube assembly (4A).


    Illustration 46g01279522


    Illustration 47g01279616

  72. 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.


    Illustration 48g01273481

  73. Install O-ring seals (142) and lip seal (143) onto carrier (141).


    Illustration 49g01280603

    Note: Discard bolts (79) and (107) and replace.

  74. 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).


    Illustration 50g01279496

  75. Install covers (139). Install carrier assembly (141) and bolts (140).

End By:

  1. Install the input speed sensor. Refer to Disassembly and Assembly, "Speed Sensor - Install".

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