525C, 535C and 545C Wheel Skidders Power Train Caterpillar

Assembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	1
C	1P-2420	Transmission Repair Stand	1
D	2P-8312	Retaining Ring Pliers	1
E	8T-5096	Dial Indicator Gp	1
F	9U-7480	Compressing Tube	1
G	1P-1863	Retaining Ring Pliers	1
H	9U-7479	Compressing Tube	1
J	1U-6341	Threaded Rod	1
K	5P-7970	Nut	1
M	1P-0520	Driver Gp	1
N	154-9731	Thread Lock Compound	1

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Illustration 1	g00960522

1. Lower the temperature of bearing (158) and bearing cup (159) . Install bearing (158) , bearing cup (159) , and seal (160) in cover (155) .

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Illustration 2	g00960379

2. Lower the temperature of bearings (156) and (157) . Install bearings (156) and (157) in cover (155) .

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Illustration 3	g00984256

3. Install magnetic screen (154) and suction screen (153) .

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Illustration 4	g00984255

4. Install cover (152) and bolts (151) .

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Illustration 5	g01272199

Note: Adjust Thickness of shims (148) to 5.0 ± 0.5 mm (0.197 ± 0.0197 inch).

5. Lower the temperature of bearing cup (150) . Install bearing cup (150) , seal (149) , and shims (148) in bearing cage (146) .

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Illustration 6	g01272164

6. Install bearing cage (146) and bolts (147) in transmission case (132) .

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Illustration 7	g00984252

7. Raise the temperature of bearing cone (145) and install bearing cone (145) and gear (144) on shaft assembly (133) .

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Illustration 8	g00984251

8. Install shaft assembly (133) .

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Illustration 9	g00986212

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Illustration 10	g00986213

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Illustration 11	g00984249

9. Lower the temperature of bearing cup (141) and install bearing cup (141) with Tooling (M) .

10. Use Tooling (M) in order to install seal (142) .

11. Install shims (140) , bearing cup (141) , seal (142) , and seal (143) in bearing cage (139) .

    ReferenceFor proper shaft end play, refer to Testing and Adjusting, RENR8891, "Bearing End Play (Output Transfer Gears) - Adjust".

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Illustration 12	g00984247

12. Install the bearing cage and install bolts (138) . Tighten bolts (138) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).

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Illustration 13	g00986214

13. Raise the temperature of bearing cone (131) . Install bearing cone (131) on shaft (133) .

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Illustration 14	g00984240

14. Lower the temperature of bearings (128) , (129) , and (130) . Install the bearings in transmission case (132) .

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Illustration 15	g00984239

15. Install thrust disc (127) in transmission case (132) .

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Illustration 16	g00984236

16. Install seals (124) and (126) on piston (124) .

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Illustration 17	g00984232

17. Balance seal assembly (124) , wave spring (123) , and piston (122) upon installation. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.

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Illustration 18	g00979099

18. Install piston (124) .

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Illustration 19	g00979091

19. Install wave spring (123) .

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Illustration 20	g00979089

20. Install balance piston (122) .

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Illustration 21	g00979073

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Illustration 22	g00979077

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

21. Position the shaft assembly so retaining ring (121) lines up with the opening on Tooling (H) .

22. Install Tooling (H) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) in order to install retaining ring (121) . Remove Tooling (H) .

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Illustration 23	g00979070

23. Use Tooling (G) to install retaining ring (120) .

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Illustration 24	g00979064

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Illustration 25	g00979063

24. Install friction discs (119) , clutch plates (118) , and end plate (117) .

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Illustration 26	g00979060

25. Install retaining ring (116) .

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Illustration 27	g00979059

26. Install ring retainer (115) and thrust disc (114) .

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Illustration 28	g00744470

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Illustration 29	g00744313
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

27. Use Tooling (E) , a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    2. Make sure that End Plate (W) is free.

    3. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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    Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    5. End Plate (W) should move upward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.

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Illustration 30	g00979056

28. Connect hub assembly (112) to gear (110) .

29. Use Tooling (G) to install retaining ring (111) .

30. Lower the temperature of bearing (113) and install bearing (113) .

    Note: After the bearing is installed, the diameter must be 79.113 ± 0.05 mm (3.1147 ± 0.002 inch).

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Illustration 31	g00979054

31. Install gear and hub assembly (110) .

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Illustration 32	g00979049

32. Install thrust disc (109) .

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Illustration 33	g00979043

33. Install gear (108) .

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Illustration 34	g00979038

34. Use Tooling (D) to install retaining ring (107) .

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Illustration 35	g00977455

35. Install thrust disc (106) .

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Illustration 36	g00977453

36. Install seal rings (105) .

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Illustration 37	g01272046

37. Use Tooling (A) and a suitable lifting device to rotate shaft assembly (78) to the opposite side. The weight of shaft assembly (78) is approximately 45 kg (100 lb).

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Illustration 38	g00977446

38. Balance seal assembly (102) , wave spring (103) , and piston (104) upon installation. Check the lips on the seals for damage or wear. Replace the seals, if necessary.

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Illustration 39	g00977444

39. Install piston (104) on the shaft.

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Illustration 40	g00977441

40. Install wave spring (103) .

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Illustration 41	g00977438

41. Install balance seal assembly (102) .

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Illustration 42	g00977426

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

42. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown).

43. Use Tooling (D) to install retaining ring (101) . Release the pressure on the wave spring and remove Tooling (F) .

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Illustration 43	g00977433

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Illustration 44	g00977424

44. Install one disc assembly (99) , clutch plates (100) , and end plate (98) .

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Illustration 45	g00977422

45. Install retaining ring (97) .

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Illustration 46	g00977380

46. Use Tooling (D) to install retaining ring (96) .

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Illustration 47	g00744470

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Illustration 48	g00744313
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

47. Use Tooling (E) , a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    2. Make sure that End Plate (W) is free.

    3. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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    Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (Z) in the shaft for the clutch that is being checked.

    5. End Plate (W) should move upward and End Plate (W) should contact Retaining ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.

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Illustration 49	g00976232

48. Install retainer (95) and thrust disc (94) .

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Illustration 50	g00976230

49. Connect hub assembly (92) to gear (90) .

50. Lower the temperature of bearing (93) and install bearing (93) in hub assembly (92) .

    Note: After bearing (93) is installed the inside diameter must be 65.046 ± 0.039 mm (2.5609 ± 0.0015 inch).

51. Use Tooling (D) to install retaining ring (91) .

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Illustration 51	g00976229

52. Install gear (90) .

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Illustration 52	g00976228

53. Install thrust disc (89) . Use Tooling (D) to install retaining ring (88) .

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Illustration 53	g00976215

54. Use Tooling (A) and a suitable lifting device to install shaft assembly (87) . The weight of shaft assembly (87) is approximately 82 kg (180 lb).

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Illustration 54	g01272168

55. Install sensor (85) and connect harness assembly (86) .

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Illustration 55	g00986223

56. Raise the temperature of bearing cone (83) and gear (84) . Turn shaft (78) in order to install bearing cone (83) and gear (84) .

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Illustration 56	g00986224

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Illustration 57	g00975867

57. Raise the temperature of carrier (80) , bearing cone (81) , and gear (82) . Install the bearings on shaft (78) .

58. Install seal ring (79) .

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Illustration 58	g00975828

59. Install input shaft assembly (78) .

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Illustration 59	g00988354

60. Install seal rings (76) and (77) on piston (75) . Replace the seals if it is necessary.

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Illustration 60	g00975818

61. Install piston seal (75) .

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Illustration 61	g00975812

62. Install wave spring (74) .

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Illustration 62	g00975811

63. Install balance seal assembly (73) .

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Illustration 63	g00975588

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Illustration 64	g00975810

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

64. Position the shaft assembly so the opening in retaining ring (72) will be in line with the opening in Tooling (F) .

65. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (G) to install retaining ring (72) . Remove Tooling (F) .

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Illustration 65	g00975587

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Illustration 66	g00975585

66. Install friction discs (71) , clutch plates (70) , and end plate (69) .

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Illustration 67	g00975584

67. Install retaining ring (68) . Use Tooling (D) to install retaining ring (67) .

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Illustration 68	g00975579

68. Install retainer (66) and thrust disc (65) .

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Illustration 69	g00744470

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Illustration 70	g00744313
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

69. Use Tooling (E) , a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    2. Make sure that End Plate (W) is free.

    3. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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    Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    5. End Plate (W) should move upward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.

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Illustration 71	g00975578

70. Reduce the temperature of sleeve bearings (64) and install sleeve bearings (64) .

    Note: Bearing (64) inside diameter must be 65.046 ± 0.039 mm (2.5609 ± 0.0015 inch).

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Illustration 72	g00975576

71. Install gear assembly (63) and thrust disc (62) .

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Illustration 73	g00975570

72. Position the shaft assembly with the opposite end upward, as shown. Install three seal rings (60) . Use Tooling (D) to install retaining ring (61) .

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Illustration 74	g00988355

73. Install seal rings (59A) and (59B) on piston (59) . Replace the seals if it is necessary.

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Illustration 75	g00975564

74. Install piston assembly (59) .

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Illustration 76	g00975562

75. Install wave spring (58) .

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Illustration 77	g00975558

76. Install balance seal assembly (57) .

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Illustration 78	g00975553

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Illustration 79	g00975555

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

77. Position the shaft so the opening in retaining ring (56) will line up with the opening in Tooling (F) .

78. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. Use Tooling (D) to install the retaining ring (56) . Remove Tooling (F) .

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Illustration 80	g00975467

79. Install one friction discs (55) , clutch plates (54) , and end plate (53) .

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Illustration 81	g00975463

80. Install retaining ring (52) .

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Illustration 82	g00975458

81. Use Tooling (D) to install retaining ring (51) .

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Illustration 83	g00744470

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Illustration 84	g00744313
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

82. Use Tooling (E) , a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    2. Make sure that End Plate (W) is free.

    3. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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    Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    5. End Plate (W) should move upward and end plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.

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Illustration 85	g00975456

83. Install retainer (50) and thrust disc (49) .

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Illustration 86	g00975454

84. Lower the temperature of sleeve bearing (48) and install sleeve bearing (48) , if necessary. Connect gear (45) to hub assembly (47) . Use Tooling (G) to install retaining ring (46) .

    Note: Bearing (48) inside diameter must be 65.046 ± 0.039 mm (2.5609 ± 0.0015 inch).

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Illustration 87	g00975452

85. Install gear and hub assembly (45) .

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Illustration 88	g00975449

86. Install thrust disc (44) . Use Tooling (D) to install retaining ring (43) .

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Illustration 89	g01272041

87. Position shaft assembly (42) on Tooling (C) , as shown.

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Illustration 90	g00974967

88. Use Tooling (A) and a suitable lifting device in order to install shaft assembly (42) . The weight of shaft assembly (42) is approximately 41 kg (90 lb).

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Illustration 91	g00988356

89. Install seal rings (41A) , and (41B) on piston (41) . Replace the seals, if necessary.

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Illustration 92	g00974965

90. Install piston seal (41) .

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Illustration 93	g00974964

91. Install wave spring (40) .

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Illustration 94	g00974963

92. Install balance seal assembly (39) .

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Illustration 95	g00974961

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Illustration 96	g00974962

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

93. Position the shaft assembly with the opening in retaining ring (38) in line with the opening in Tooling (F) .

94. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to install retaining ring (38) and remove Tooling (F) .

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Illustration 97	g00974960

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Illustration 98	g00974959

95. Install friction discs (37) , clutch plates (36) , and end plate (35) .

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Illustration 99	g00974958

96. Install retaining ring (34) .

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Illustration 100	g00974957

97. Use Tooling (D) to install retaining ring (33) .

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Illustration 101	g00744470

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Illustration 102	g00744313
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

98. Use Tooling (E) , a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    2. Make sure that End Plate (W) is free.

    3. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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    Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    5. End Plate (W) should move upward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.

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Illustration 103	g00974956

99. Install retainer (32) and thrust disc (31) .

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Illustration 104	g00974955

100. Connect gear (27) to hub assembly (29) . Use Tooling (G) to install retaining ring (28) . If necessary, lower the temperature of bearing (30) and install sleeve bearing (30) .

     Note: Bearing (30) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).

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Illustration 105	g00974954

101. Install hub assembly (27) , thrust disc (26) , and the gear.

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Illustration 106	g00974953

102. Install spacer assembly (25) .

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Illustration 107	g00974951

103. Install gear (24) and washer (23) .

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Illustration 108	g00974950

104. Install thrust disc (22) .

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Illustration 109	g00974949

105. Reposition the shaft assembly, as shown. Install three seal rings (20) . Use Tooling (D) to install retaining ring (21) .

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Illustration 110	g00974948

106. Balance seal assembly (17) , wave spring (18) , and piston (19) upon installation. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.

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Illustration 111	g00974947

107. Install piston assembly (19) .

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Illustration 112	g00961678

108. Install wave spring (18) .

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Illustration 113	g00961656

109. Install balance seal assembly (17) .

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Illustration 114	g00961639

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Illustration 115	g00961647

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Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

110. Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) .

111. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to install retaining ring (16) . Remove Tooling (F) .

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Illustration 116	g00961630

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Illustration 117	g00961507

112. Install friction discs (15) , clutch plates (14) , and end plate (13) .

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Illustration 118	g00961492

113. Install retaining ring (12) .

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Illustration 119	g00961468

114. Install retaining ring (11) .

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Illustration 120	g00744470

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Illustration 121	g00744313
Typical Example (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

115. Use Tooling (E) , a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

     1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

     2. Make sure that End Plate (W) is free.

     3. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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     Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

     4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

     5. End Plate (W) should move upward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.

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Illustration 122	g00961455

116. Install retainer (10) and thrust disc (9) .

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Illustration 123	g00961444

117. Use Tooling (G) to install retaining ring (6) .

118. Connect hub assembly (7) and gear (5) . If necessary, lower the temperature of bearing (8) and install sleeve bearing (8) .

     Note: Bearing (8) inside diameter must be 65.046 ± 0.039 mm (2.5609 ± 0.0015 inch).

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Illustration 124	g00961435

119. Install gear and hub assembly (5) .

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Illustration 125	g00961189

120. Use Tooling (D) to install retaining ring (3) and install thrust disc (4) .

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Illustration 126	g01272038

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Illustration 127	g00984312

121. Use Tooling (A) and a suitable lifting device to remove shaft assembly (1) from Tooling (C) and into the transmission case. The weight of shaft (1) is approximately 50 kg (110 lb).

     Note: Hold input shaft (2) away from shaft assembly (1) for clearance.

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Illustration 128	g00748030

122. Use shims to obtain a thickness of 0.05 mm to 0.15 mm (0.002 inch to 0.006 inch). Use Tooling (E) to check the end play on the output shaft and the input shaft.

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Illustration 129	g00748037

123. Use shims to obtain a thickness of 0.05 mm to 0.15 mm (0.002 inch to 0.006 inch). Use Tooling (E) to check the end play on the input shaft.

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Illustration 130	g00984245

124. Install parking brake group (137) . Install bolts (136) . Tighten bolts (136) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).

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Illustration 131	g01272211

125. Apply Tooling (N) to the threads of bolt (134) .

126. Install yoke (134A) , the retainer, and bolt (134) . Tighten bolt (134) to a torque of 120 ± 20 N·m (89 ± 15 lb ft).

127. Install brake drum (135) and bolts (135A) . Tighten bolts (135A) to a torque of 120 ± 20 N·m (89 ± 15 lb ft).

End By: Connect the transmission and the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Connect".