735C, 740C EJECTOR and 745C Articulated Trucks Power Train Caterpillar

Assembly Procedure

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Illustration 1	g06049267

1. Replace all gaskets and inspect O-ring seals for serviceability. Check for breaks and creases in all gaskets and indentations in the metal gaskets. Replace if necessary. Replace O-ring seals if necessary.
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   Illustration 2	g03850927

2. Position a new metal gasket under hub assembly with raised geometry facing up. Install the O-ring seal on to the hub assembly. Install hub assembly (167).
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   Illustration 3	g03851532

3. Position a new metal gasket and install housing (165). Install 11 bolts (164).

   1. Add two bolts 180° apart and tighten by hand.

   2. Add remaining bolts and tighten by hand.

   3. Torque bolts to 28 N·m (21 lb ft) in an alternating sequence 180° apart. Then re torque to confirm torque.

4. Install new ring seal (166) with the lip (skirt) opening facing down.
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   Illustration 4	g03850885

5. Install roller bearing inside housing (163) so it is flush with the top of the housing. Position a new gasket and install housing (163). Install two M8 and six M10 bolts (161) and the thin washers.

   Note: Do not substitute washers as interference will occur.

6. Install seals (160) and (162) and lubricate with the fluid being sealed.

7. Install bearing (159) with the orientation marked from the disassembly.
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   Illustration 5	g03850908

8. Install the ring seals onto shaft (158) and lubricate with the fluid being sealed. Install shaft (158).
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   Illustration 6	g03850860

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   Illustration 7	g06292825

9. Install the O-ring seal and ring seals on low gain piston (156). Install the lip (skirt) opening facing down on low gain piston (156).

10. Install the O-ring seals on high gain piston (157). Lubricate the seals with the fluid being sealed.

11. Install pistons (157) and (156).

    Note: Align high gain piston (157) dowel with the hole in hub (153).

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    Illustration 8	g03850828

12. Install 16 springs (154) and 21 springs (155).
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    Illustration 9	g03850802

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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.

13. Install a new gasket and hub (153). Install 26 bolts (152) and the washers hand tight then torque to standard torque.
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    Illustration 10	g03851696

14. Install hub assembly (147) and retaining ring (144).

15. Install ring seals (146) and lubricate with the fluid being sealed. Install bearing (145) in orientation from the disassembly.
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    Illustration 11	g03851981

16. Install six clutch No. 6 plates (151) and six friction disks (150) starting with a clutch plate.

17. Install end plate (149) with the flat side down and retaining ring (148).
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    Illustration 12	g03850700

18. Install end clutch plate (143) for clutch No. 1.

    Note: Install with ID step facing up.

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    Illustration 13	g03850580

19. Install hub (142).

20. Alternately Install three friction disks (141) and three clutch plates (141) starting with the friction disks. Install the bottom piston clutch retaining ring.
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    Illustration 14	g06420096

21. Install pin (138). Apply Tooling (E) to the threads of set screw (137). Install and tighten set screw (137) to a torque of 12 ± 3 N·m (106 ± 27 lb in). Repeat for the opposite side.

22. Install sleeve bearing (139B). If necessary use Tooling (K) to install sleeve bearing (139B)
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    Illustration 15	g03850519

23. Install the inner ring seal. and outer ring seals on piston (134). Install the outer ring seal with the lip facing towards the housing. Install piston (134).

24. Install the outer ring seals on piston (134) with the lip (skirt) facing down. (Do not over stretch)

25. Lubricate the seals with the fluid being sealed.
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    Illustration 16	g03850511

26. Install two springs (132) opposite as shown and plate (133).
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    Illustration 17	g03850139

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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.

    Note: Start with four screws located 90 degrees apart from each other and snug them up until just contacting the piston by hand without compressing the piston. Then tighten further down alternating across 180 degrees from each other to slowly compress the springs. Progressing too much at a time will cause the springs to slide, thus causing the piston to cock one side. Once the piston has bottomed out, the edge of the piston will be flush to the top of the housing. Install the remaining bolts and torque all bolts to specification.

27. Install balance piston (131) and screws (130). Tighten screws (130) to a torque of 12 ± 3 N·m (106 ± 27 lb in).

    Note:

28. Repeat steps 19 through 24 for the opposite side.
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    Illustration 18	g03850542

29. Apply Tooling (F) to secure eight thrust buttons (135) to the clutch piston assembly.
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    Illustration 19	g03850078

30. Install clutch piston assembly (129) with the thrust buttons down. Install top piston clutch retaining ring (128).
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    Illustration 20	g03852159

31. Remove two bolts 180° apart from the piston assembly and attach a suitable lifting device. Install hub assembly (127) and O-ring seals (124). Lubricate O-ring seals (124) lightly with lubricant that is being sealed. Tighten the bolts removed from the piston assembly to a torque of 12 ± 3 N·m (106 ± 27 lb in).
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    Illustration 21	g03852208

32. Install bearing (118) into gear (119).

33. Install gear (119) and thrust washers (117) and (120) into the carrier.

34. Install shaft (115) into carrier (121).
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    Illustration 22	g03852229

35. Install spring pin (116) into shaft (115) flush with the carrier assembly.

36. Repeat Steps 29 through 32 for the remaining gear assemblies.
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    Illustration 23	g03849806

37. Install ring seals (113). Apply Tooling (F) to the grooves and ring seals (113) to keep the seals secure to the carrier assembly when installing.

    Note: Tooling (F) is critical in preventing damage to seals (113) during the carrier installation.

38. Position retaining ring (111). Compress retaining ring (111) to install gear (112).
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    Illustration 24	g03852183

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    Illustration 25	g06014133

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    Illustration 26	g03874621

39. Position carrier assembly (109). Install Tooling (J) on to carrier assembly (109). Turn the latch 1/4 turn to lock the latch. Screw Tooling (J) to the carrier. Turn the handles evenly until the carrier bottoms out and the retaining ring groove becomes visible. The groove will be slightly recessed.

    Note: Even downward pressure will prevent seals (113) from dislodging from the carrier.

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    Illustration 27	g03852352

40. Position retaining ring (110) over shaft next to the groove.

    Note: Lifting slightly on the center shaft from the bottom will allow the retaining ring to be installed in to the groove. Slightly tap the retaining ring in place. Do not lift on the center shaft by installing and eye bolt on top as damage may occur to the shaft.

41. Install plastic seals (111a). Lubricate seals (111a) lightly with the lubricant being sealed.

42. Install eight thrust buttons (114).

43. Alternately Install four clutch No.3 clutch plates (126) and four friction disks (125) starting with clutch plates (126).

44. Install end plate (123) (flat side down) and retaining ring (122)
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    Illustration 28	g03852481

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    Illustration 29	g06038454

45. Install the gear and retaining ring (108) into housing (107).

46. Install clutch hub (105) and retaining ring (106) on to the hub.

47. Install the hub assembly into clutch housing (107).

48. Install No. 2 clutch end clutch plate (104).
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    Illustration 30	g03849713

49. Alternately Install three friction discs (102) and three clutch plates (101) starting with the friction discs.

50. Install spring (103).
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    Illustration 31	g03849705

51. Install retaining ring (99).

52. Install the ring seal in clutch piston (100) with the lip facing up.

53. Install clutch piston (100).
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    Illustration 32	g03852560

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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.

54. Install the ring seal on plate (98) with the lip facing down. Lubricate the O-ring seal and shaft lightly with lubricant that is being sealed. Install the O-ring seal and plate (98).

    Note: Do not use old retaining ring (96). Install a new retaining ring (96).

55. Use Tooling (D) to compress plate (98). Install retaining ring (96). Slowly decompress Tooling (D) and remove.
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    Illustration 33	g03852635

56. Use Tooling (F) to secure eight thrust buttons to gear assembly (95).

57. Install gear assembly (95) and retaining ring (94).
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    Illustration 34	g03852682

58. Install clutch assembly (93).

    Note: Slowly install clutch assembly over the rotating seals.

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    Illustration 35	g03852703

59. Position cylinder (90) onto the carrier assembly and install retaining ring (91).

60. Install bearing sleeve (84).

61. Install bearings (86) and (88) into gear (87).

62. Install gear (87) and thrust washers (85) and (89).

63. Remove the spring pin from shaft (82) and install shaft (82).
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    Illustration 36	g03853089

64. Press spring pin (82) into shaft (83) flush with the carrier assembly.

65. Repeat Steps 58 through 62 for the remaining gear assemblies.
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    Illustration 37	g03853162

66. Apply Tooling (F) to secure eight thrust buttons (92) to the carrier assembly.
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    Illustration 38	g03853174

67. Install carrier assembly (81) and the retaining ring.
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    Illustration 39	g03858430

68. Apply Tooling (F) to eight thrust buttons (80) and install.

69. Install the O-ring seals and ring seal onto gear (76). Lubricate the seals with the fluid that is being sealed. Install gear (76) and retaining ring (79) onto gear assembly (77).
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    Illustration 40	g03858284

70. Install gear (76) and gear assembly (77) as a unit. Install seals (78).

71. Lubricate the seals with the lubricant that is being sealed.
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    Illustration 41	g06038399

72. Install the ring seals onto shaft (74). Install shaft (74).
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    Illustration 42	g03849260

73. Install a new gasket onto planetary assembly.

74. Attach a suitable lifting device to transmission housing (73). The weight of transmission housing (73) is approximately 113 kg (250 lb).

75. Remove transmission housing (73) from Tooling (A) and position level onto the planetary assembly.

    Note: Location pins line the housing up to the manifold.

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    Illustration 43	g03849202

76. Install bolt (8) with one washer and bolt (9) with three washers.

    Note: Failure to install bolts (8) and (9) will result in the planetary failing out when rotating.

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    Illustration 44	g03849273

77. The combined weight of transmission housing (73) and the planetary assembly is approximately 340 kg (750 lb).

78. Remove transmission housing and planetary assembly from Tooling (C) and secure onto Tooling (A).
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    Illustration 45	g03849181

79. Install intermediate speed sensor assemblies (70) and (72). Install cover (71).

80. Install O-ring seals (69).
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    Illustration 46	g03849162

81. Install the ID and OD ring seals on piston (66) with the lip (skirt) facing down. Lubricate the seals with the lubricate being sealed. Install piston (66) into clutch housing (68).

82. Install thrust washer (67).

83. Install the assembly into the transmission housing.
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    Illustration 47	g03853599

84. Install ring gear (61).

85. Install six dowel pins (62) and six springs (63).
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    Illustration 48	g03853646

86. Alternately Install three No. 5 friction disks (65) and three clutch plates (64) stating with the friction discs.
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    Illustration 49	g03853681

87. Install piston housing (58) and 12 bolts (57).

    Note: Orientation of piston housing (58) should be correctly oriented with clutch housing (68).

88. Install the ring seals on piston (59) with the lip (skirt) facing down. Lubricate the seals with the fluid being sealed.

89. Install piston (59).
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    Illustration 50	g03853759

90. If necessary, install bearing sleeve (49).

91. Install bearings (51) and (53) into gear (52).

92. Position thrust washers (50) and (54) and install gear (52).

93. Remove spring pin from shaft (47). Install shaft (47) into carrier assembly.
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    Illustration 51	g03848983

94. Install spring pin (48) into shaft (47) flush with the carrier assembly.

95. Repeat 88 Steps 92 through for the remaining gear assemblies.
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    Illustration 52	g03848560

96. Install retaining ring (46) and compress while installing hub (45).
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    Illustration 53	g03853885

97. Apply Tooling (F) to secure eight thrust buttons (56) and install thrust buttons (56).
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    Illustration 54	g03848531

98. Orient carrier assembly as shown. Attach Tooling (B) and a suitable lifting device to carrier assembly (44). The weight of carrier assembly (44) is approximately 34 kg (75 lb). Install carrier assembly (44).

    Note: If carrier assembly (44) does not seat properly, check for proper thrust button installation.

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    Illustration 55	g03848519

99. Install five dowel pins (41) and plate (43). Install five springs (42).
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    Illustration 56	g03848359

100. Install two No. 4 clutch plates (40) and three friction discs (39) starting with the friction discs.
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     Illustration 57	g03848299

101. Install end plate (38) on the next set of splines.
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     Illustration 58	g03848079

102. Install retaining ring (36). Compress retaining ring (36) and install gear (37). Apply Tooling (F) to thrust buttons (35) and install eight thrust buttons (35).
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     Illustration 59	g03854289

103. Install bearings (31) and (33) into gear (32).

104. Install thrust washers (30) and (34) and gear (32).

105. Remove the spring pin from shaft (27) and install shaft (27).
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     Illustration 60	g03854383

106. Install shaft (27). Install spring pin (28) into shaft (27) flush with the inside of the carrier assembly indent.

107. Repeat steps 97 through 100 for the remaining gear assemblies.
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     Illustration 61	g03847725

108. Install rotor sensor (26) and bolts (25).
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     Illustration 62	g03847720

109. Install bearing (23) and retaining ring (22).

110. Install roll pin (24).
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     Illustration 63	g03847644

111. Install retainer (19) and retaining ring (18).

112. Install bearing cone (20) and spacer (21).
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     Illustration 64	g03855768

113. Attach a suitable lifting device to carrier assembly (15). The weight of carrier assembly (15) is approximately 36 kg (80 lb). Install carrier assembly (15).
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     Illustration 65	g03847542

114. Install two bearing cups and bearing cone (17). Use Tooling (G) to install new lip seal (16) Lubricate the seals with the fluid that in being sealed.
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     Illustration 66	g03855776

115. Position a new gasket and install the rear cover assembly. Install 24 bolts (12) and the washers.

     Note: Prior to tightening bolts (12) there will be a minimum 5 mm (0.2 inch) between the rear cover and the case.

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     Illustration 67	g03855813

     Note: Installing the yoke assembly will seat the bearing.

116. Use Tooling (H) to install wear sleeve (14) onto yoke assembly (11).

117. Position yoke assembly (11) and install the two lubricated O-ring seals, the plate, the washer and bolt (13).

118. Install output speed sensor assemblies (10).
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     Illustration 68	g06045516

119. Use Tooling (A) to rotate the transmission 180 degrees.

120. Remove bolt (8) and the washers. Ensure bolt (9) is installed and torqued.
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     Illustration 69	g03845633

121. Install three outside (M12) bolts (6) and the washers.

122. Position a new gasket and install cover/manifold (7).

123. Install bolts (5) and the washers a torque to 63 ± 2 N·m (46 ± 1.5 lb ft).

     Note: Note the length of the cover/manifold bolts.

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     Illustration 70	g03845629

124. Install pump (4). Ensure that the pump is fully seated. Install eight bolts (3) and the washers.
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     Illustration 71	g03842227

125. The torque converter is easier to install with cover (2) removed.

126. Install the transmission wiring harness and the associated brackets.

End By:

1. Install the torque converter.