918F WHEEL LOADER POWER TRAIN Caterpillar


Differential (Limited Slip)

Usage:

Disassemble Differential (Limited Slip) (918F, IT18F, 924F, IT24F, & 924G)

Start By:

a. remove differential

NOTE: The following procedure is for the disassembly of TRACHTECH INC. Limited Slip Differentials.

1. Remove twenty bolts (1).

2. Remove bevel gear (2) from case housing (3).

3. Invert bevel gear (2) and remove thrust washer (4).

4. Measure the end play gap, as follows:

a. Install tooling (A) on the differential assembly, as shown.

NOTE: The center pusher bolt of tooling (A) must have M16 x 2.0 thread to apply the proper preload on the disc packs.

b. Tighten the center bolt of tooling (A) to a torque of 27 N·m (29 lb ft) to apply 900 kg (2000 lb) of preload on the disc packs.

c. Mount the magnetic base of tooling (B) on Face A of the case housing.

d. Zero the dial indicator on Face A, as shown.

e. Carefully rotate the magnetic base of tooling (B) until the dial indicator is touching Face B (the disc pack).

f. Record the indicator reading.

g. Record two additional indicator reading from different areas of Face B.

h. Average the three indicator readings. This is the measured end play gap.

i. If the end play gap in Step 4h was greater than 0.81 mm (0.032 inch), replacement of the existing disc packs is necessary.

5. Remove the disc pack from the case housing. The disc pack consists of two friction discs (5) and two plates (6).

6. Remove actuator housing (7) and gear (8) from the case housing, as shown.

7. Remove pinion shaft (10) and two pinion gears (9).

8. Remove the remaining pinion shaft (12) and two pinion gears (11).

9. Remove two pinion gears (9) from pinion shaft (10). Repeat for the remaining pinion shaft (12) and pinion gears (11).

10. Remove gear (13) from the case housing.

11. Remove actuator housing (14) from the case housing by lifting straight upward, as shown.

12. Remove the disc pack from the case housing. The disc pack consists of two friction discs (16) and two plates (15).

13. Remove thrust washer (17).

Assemble Differential (Limited Slip) (918F, IT18F, 924F, IT24F, & 924G)

1. Clean and inspect all parts of the differential. If any of the parts are worn or damaged, use new parts for replacement.

2. Install thrust washer (17) in the case housing. Lubricate the thrust washer face with clean axle oil.

3. Replace the disc packs if:

a. The stack heights of the disc packs are NOT symmetrical within 0.10 mm (.004 inch).

b. The disc friction material is worn such that the discs, are running steel on steel.

4. When replacement of the disc packs is required, replace with the disc packs of the same type. If THIN is marked on the case housing, replace with two new THIN disc packs. If THICK is marked on the case housing, replace with two new THICK disc packs. Do not mix disc packs. Use two THIN or two THICK. Do not use one of each.

NOTE: Use clean axle oil to thoroughly lubricate plates and friction discs, prior to assembly.

5. Install two friction discs (16) and two plates (15) in alternate order in the case housing starting with a plate and ending with a friction disc, as shown.

6. Align the keys of actuator housing (14) with the slots of the case housing and install, as shown.

7. Install gear (13) in the case housing.

NOTE: Turn the gear slowly until the spline engages with the two friction discs installed in Step 5. Make sure the gear is fully seated.

8. Install two pinion gears (9) on pinion shaft (10). Repeat for remaining pinion shaft (12) and two pinion gears (11). Lubricate with clean axle oil.

9. Install pinion shaft (12) and two pinion gears (11) in the case housing, as shown.

10. Rotate pinion gears (11) slightly until the pinion shaft rests in the V-slots of the actuator housing.

11. Install the remaining pinion shaft (10) and two pinion gears (9) in the case housing, as shown.

12. Assemble gear (8) and actuator housing (7) on bench, as shown. Align the keys of the actuator housing with the slots in the case and install, as shown.

NOTE: Use clean axle oil to thoroughly lubricate plates and friction discs, prior to assembly.

13. Install two friction discs (5) and two plates (6) in alternate order in the case housing starting with a friction disc and ending with a plate.

NOTE: Steps 14 through 21 describe the proper procedure for measuring end play gap.

14. Install tooling (A) on the differential assembly, as shown.

NOTE: The center pusher bolt of tooling (A) must have M16 x 2.0 thread to apply the proper preload on the disc packs.

15. Tighten the center bolt of tooling (A) to a torque of 27 N·m (20 lb ft) to apply 900 kg (2000 lb) of preload on the disc packs.

16. Mount the magnetic base of tooling (B) on Face A of case housing.

17. Zero the dial indicator on Face A, as shown.

18. Carefully rotate the magnetic base of tooling (B) until the dial indicator is touching Face B, (the disc pack).

19. Record the indicator reading.

20. Record two additional indicator readings from different areas of Face B.

21. Average the three indicator readings. This is the measured end play gap.

NOTE: If the existing disc packs were installed in Step 4, continue with Step 22. If new disc packs were installed in Step 4, continue with Step 23.

22. If the end play gap in Step 21 was greater than 0.81 mm (0.032 inch), replacement of the existing disc packs is necessary.

NOTE: Steps 23 though 28 are for new replacement disc packs.

23. When replacement of the disc packs is required, replace with disc packs of the same type. If THIN is marked on the case housing, replace with two new THIN disc packs. If THICK is marked on the case housing, replace with two new THICK disc packs. Do not mix disc packs. Use two THIN or two THICK. Do not use one of each.

24. With new disc packs installed in the limited slip differential, measure the end play gap as described in Steps 14 though 21. The measured end play gap must fall between 0.203 and 0.508 mm (0.0080 and 0.0200 inch).

25. If the measured end play gap is greater than 0.508 mm (.0200 inch) and two THIN disc packs were installed, remove two THIN disc packs and install two THICK disc packs. Measure the end play gap again to determine if it falls between 0.203 and 0.508 mm (0.0080 and 0.0200 inch) to meet specifications.

26. If the measured end play gap still does not meet specifications, replace the pinion shafts and or both actuator housings. Install either two THIN or two THICK disc packs to obtain an end play gap that falls between 0.203 and 0.508 mm (0.0080 and 0.0200 inch) to meet specifications.

27. If the disc packs were changed from the kind marked on the outside surface of the case housing, replace the existing mark with either THICK or THIN for future reference.

28. Install thrust washer (4) in bevel gear (2). Lubricate the thrust washer face with clean axle oil.

NOTE: Apply a small amount of grease to the back side of the thrust washer prior to installing. This will retain the thrust washer in place while installing the bevel gear.

29. Invert bevel gear (2) install on case housing (3).

NOTE: The bevel gear is a light press fit to the case housing. It is important to tighten bolts (1) evenly, to properly seat the bevel gear.

30. Install twenty bolts (1). Tighten bolts (1) to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

End By:

a. install differential

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