Usage:
Tools Required:
NOTE: The following photographs show the removal/installation procedure for a typical output transfer drive assembly. The procedure is similar for 'C' trucks and the D400 - where there are differences, these are noted and specific instructions are given.
1. Stop the truck in the straight ahead position and apply the parking brake. Move the gear lever to the Neutral position and stop the engine. Remove the key and place suitable warning notices to prevent personnel starting the engine and operating the controls. Use the hand lever on the suspension control valve to fully lower the front suspension.
2. With the oil warm, remove the drain plug (1) and allow the oil to drain into a suitable container (C Truck - 35 litres) (D400 - 105 litres).
3. Remove the transmission compartment grille (2).
4. Release the retaining clips (3) from the access door struts (4).
5. Remove the rear access door assembly (5).
6. Disconnect and remove the hoist control linkage and rod assembly.
7. C-trucks: Remove the cam housing cover (6). Disconnect and remove the selector cable (7) from the housing. Refit the cover (6) to prevent dirt entering the housing.
8. D400: Disconnect the torque converter lock up oil line (8) from the transfer gearbox.
9. D400: Disconnect the transmission control cables (9) from the rear of the transmission control group housing.
10. Trucks fitted with supplementary steering: Remove the supplementary steer hoses (10 and 11) from the diverter valve (12) to the pipes (13) and (14). Plug the ports on the diverter valve and cap the hoses to prevent contamination.
11. Trucks fitted with supplementary steering: Remove both pipe assemblies (13) and (14) from the supplementary steer pump.
12. Trucks fitted supplementary steering: Remove the supplementary steer pump (15).
13. Remove the bolts that secure the transmission drive shaft (16). Remove the drive shaft. D400 (early trucks) - Disconnect the wires (17) from the magnetic pick-up. Mark the wires to ensure correct reconnection.
14. Remove the bolts that secure the spider (18). Remove the spider.
15. Remove the cotter pin (19) and the clevis pin (20) from the differential lock actuator.
16. Remove the bolts securing the output transfer drive rear output yoke to the centre drive shaft (21). Slide the centre drive shaft backward.
17. D400 - Remove the bolts securing the torque converter valve group (22) to the transmission mounting bracket. Disconnect the valve group oil supply line (24). Move the valve group to allow clearance when the transmission and output transfer drive assembly is hoisted out of the compartment. Remove the oil filler tube assembly (25). Disconnect the remaining oil lines (26) and (27) from the front of the transmission. Disconnect the oil cooler return line (23).
18. C Trucks - Disconnect the oil lines (28-34) from the front of the transmission. Mark the oil lines to ensure correct reconnection. Plug the ports and cap the hoses to reduce oil spillage and prevent contamination.
19. All trucks - Disconnect the sump line connection (35) from the output transfer drive housing.
20. D400 - Disconnect the torque converter drain line (36) from the output transfer drive housing.
21. Remove the upper bolts (37) securing the left and right hand mounting brackets (38).
NOTE: On current trucks it is not necessary to remove the left and right hand mounting brackets.
22. Remove the bolts securing the upper transmission mounting assembly (39). Remove the mounting assembly. Remove the torque converter selector valve (40) to provide more clearance.
NOTE: Place a wooden plank or similar form of protection at the rear of the transmission compartment. This will prevent damage to any components when the upper transmission mounting assembly is removed and the transmission/output transfer drive assembly pivots backwards.
23. Place a suitable hoisting sling around the assembly as shown and connect the sling to a hoist.
24. Early trucks: If necessary, disconnect the steering line pipe connections (41), also ...
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It is important that the complete assembly is securely supported by the hoist and sling during the following procedure. This will prevent the assembly from moving downward when finally released from the truck frame, thus avoiding the possibility of injury or damage. |
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25. Early trucks: ... slacken the mounting brackets for both pipes (42) to allow sufficient movement of the pipes to provide clearance for the output transfer drive assembly during the hoisting procedure.
26. Drill out the indented lip of the locating ring (43) and remove the locating ring using tool 6V3133 Spanner Wrench. Remove the bolts (44) from the left and right hand pivot pins. Remove the pivot pins (45).
27. Remove the remaining lower bolts (46) from the left and right hand mounting brackets. Remove both mounting brackets (38).
28. Hoist the complete transmission/output transfer drive assembly out of the truck.
29. Lower the assembly on to suitable stands, disconnect the hoist and remove the sling.
30. Attach a sling and hoist to the transmission. Install two 3/8 - 16NC forcing bolts (47) to separate the transmission from the output transfer drive. Remove the transmission from the output transfer drive. The weight of the transmission is 622 kg (1370 lb.).
31. End by:
(a) Disassemble output transfer drive.
(b) Disassemble transmission - see CAT Form Number SENR 2393 '615 Tractor-Scraper Power Train-Disassembly and Assembly' which can be found in CAT Service Manual SENR 2386 '615 Tractor-Scraper'.
Install Output Transfer Drive
New Parts Required:
Tools Required:
1. Start by:
(a) Assemble output transfer drive
(b) Assemble transmission - see CAT Form Number SENR 2393 '615 Tractor-Scraper Power Train-Disassembly and Assembly' which can be found in CAT Service Manual SENR 2386 '615 Tractor-Scraper.'
2. Attach a sling and connect to a hoist. Lower the assembly into position in the transmission compartment. Take care when lowering past the steering system pipes. The two pipes, slackened previously in "Remove Output Transfer Drive" procedure - steps 24 and 25, can be moved to provide the clearance necessary to position the assembly in the compartment.
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It is important that the complete assembly is securely supported by the hoist and sling during this procedure. |
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3. Position the left and right hand mounting brackets (1) against the output transfer drive. Install the lower bolts and washers (2) initially and fully tighten to a torque setting of 360±47 Nm (265±35 lb.ft.).
NOTE: On current trucks the transmission and output transfer drive assembly can be installed with the left and right hand mounting brackets in position.
4. Position the assembly so that the pivot pins (3) can be installed through the right and left hand mounting brackets (1). Install the pivot pins. Be sure the slot in each pin is facing towards the front of the truck.
5. Install the bolts (4) and washers and tighten to a torque setting of 360±47 Nm (265±35 lb.ft.).
6. Install the locating ring (5). Use tool 6V3133 Spanner Wrench to tighten the locating ring until it just touches the face of the mounting bracket (1). Measure the gap (6) on each side of the truck and adjust the locating rings until both dimensions are equal to within 2mm.
7. Lock the locating ring (5) in position by using a punch to indent the ring lip into the slot in each pivot pin (3).
8. Check the alignment of the transmission to the front axle. The centre lines of the transfer drive output shaft and the front differential input shaft must be within 1.5mm (0.06 inch) measured sideways. Measure by placing a straight edge across the machined surfaces of the respective yokes.
Shims (7) are installed between the bearing cap (8) and the front suspension frame (9). If adjustment is necessary remove shims from under one bearing cap and install the same shims under the bearing cap on the other side. Before carrying out adjustment slacken clamp bolts (10). Tighten fully after adjustment.
9. Install upper bolts (2) and washers to the left and right hand mounting brackets (1). Fully tighten to a torque setting of 360±47 Nm (265±35 lb.ft.).
10. Early trucks: Connect steering pipes (11).
11. Early trucks: Connect brackets (12) to the truck frame.
12. Install a wooden plank behind the transmission then remove the hoist and sling.
13. Install the upper transmission mounting bracket assembly (13).
14. 'C' Trucks & D400: Connect the sump line (14) to the front of the output transfer drive housing using a new seal.
15. D400: Connect the torque converter drain line (15) to the front of the output transfer drive housing.
16. C Truck - Connect the oil lines (16-22) to the transmission housing using new seals.
17. D400 - Install the torque converter valve group (23) to the transmission mounting bracket (24). Connect the valve group oil supply line (26). Install the oil filler tube assembly (28) using a new gasket. Install the remaining oil lines (25 and 27) to the front of the transmission and the oil cooler return line (29) using new seals.
18. Slide the centre drive shaft (30) forward and connect it to the output yoke. Tighten the bolts to a torque setting of 135±14 Nm (100±10 lb.ft.).
19. Position the differential lock actuator shaft on the differential selector shaft and install clevis pin (31). Insert a new cotter pin (32) making sure that sufficient washers are installed under the cotter pin to take up all free play on the clevis pin.
20. Install the spider (33) connecting the front drive axle to the output transfer drive.
21. Install the transmission drive shaft (34). C Trucks:
The transmission drive shaft should have between 4 and 10mm sliding allowance between the male and female parts. Measure the distance between the machined faces of the two spider and bearing assemblies with the shaft fully compressed. Install the drive shaft then adjust the top transmission mounting until the distance between the same two faces is 4-10mm greater than the fully compressed dimension.
D400:
A clearance of 5-6mm should exist between the rear face of the input yoke and the face of the cage of the transmission input transfer gear. The clearance is obtained by adjusting the top transmission mounting. The above clearance is for a truck on wheels. If supported on stands the clearance should be 3-4mm.
Note for all trucks:
The method of adjusting the top transmission mounting depends on the arrangement fitted. On early trucks adjustment is achieved by fitting washers under the head of the bolt which passes through the mounting. On later trucks adjust the number of shims between the mounting block and the truck frame.
22. C trucks - Install the selector cable (35) to the cam housing (36). Install the cover (37) with a new gasket if necessary. Refer to "Transmission Control Linkage Adjustment - C Trucks" if adjustment is required.
23. D400 - Install the transmission control cables (38) to the rear of the transmission control group housing. Refer to "Transmission Control Linkage Adjustments - D400" if adjustment required.
24. Connect the hoist control linkage and rod assembly.
25. Trucks equipped with supplemental steering: Install the supplemental steer pump (39) using a new gasket. Tighten the nuts to a torque setting of 100±14 Nm (75±10 lb.ft.).
26. Trucks equipped with supplemental steering: Install the two pipe assemblies (40 and 41) to the supplemental steer pump. Install the two hose assemblies (42) to the pipe assemblies (40 and 41) and to the connections at the diverter valve (43). Tighten all bolts to a torque setting of 100±14 Nm (75±10 lb.ft.) except the bolts into the diverter valve which are tightened to 80±4 Nm (60±3 lb.ft.). Use new seals
27. D400: Install the torque converter lock up oil line (44) to the output transfer drive.
28. Install the rear access doors assembly.
29. Install the retaining clips (45) to the access door struts.
30. Early trucks: Install the transmission compartment rear grille (46).
31. End by:
a) Fill transmission with oil.
b) Top up hydraulic tank.
Disassemble Inter Axle Differential
Start by:
a) Remove inter-axle differential.
1. Remove bearing cone (1).
2. Remove the screws (12 off) securing the drive dog (2) to the housing.
3. Remove the bearing cone (3).
4. Remove the locking wire from all bolts (8 off) securing gear (4) to the housing assembly. Remove all bolts (5).
5. Install two 1/2" UNC forcing bolts to separate gear (4) from the housing. Remove the gear. Mark the gear and housing to ensure correct alignment upon reassembly.
6. Remove the bolts (6).
7. Separate the housing assembly ...
8. ... to reveal the gearing arrangement.
9. Remove the thrust washers (7) - 8 off.
10. Remove the gears (8) - 8 off.
11. Remove the thrust washers (9) - 8 off.
12. Remove the thrust washer (10).
13. Remove gear (11).
14. Remove gear (12).
15. Remove thrust washer (13).
16. Remove all pins (14) - 4 long and 4 short. Note the location of both types of pins to ensure correct reassembly.
Inspect/Replace Worn Parts
1. Clean and inspect the long (1) and short (2) pins for excess wear or scoring. Replace if excessively worn.
2. Clean and inspect the input gear (3) for burrs, excessive or incorrect wear or other damage. Stone away any burrs and replace if damaged.
3. Inspect the small gears (4) for wear and the plain bearings within each gear for wear or scoring.
4. Inspect all thrust washers (5) for excessive wear and replace as necessary.
Assemble Inter Axle Differential
New Parts Required
1. Install all pins - 4 long (1) and 4 short (2) into the housing as shown.
2. Install thrust washer (3).
3. Install gear (4).
4. Install gear (5).
5. Install thrust washer (6).
6. Install eight thrust washers (7).
7. Install eight gears (8).
8. Install eight thrust washers (9).
9. The lower housing assembly is shown complete and ready for further assembly.
10. Install housing (10) on to the completed lower housing assembly (11) using roll pin (12) to ensure correct assembly.
11. Install four bolts (13) and tighten evenly to a torque setting of 102 ± 15 Nm (75 ± 10 lb.ft.).
12. Use a suitable solvent to thoroughly clean and degrease the mating surfaces of the gear (14) and the housing and the tapped holes in the housing. Apply a coating of 2U2856 retaining compound to the mating surfaces. Install gear (14). Position the gear so that the four long pins locate into the four recessed holes in the mating surface of the gear.
13. Install bolts (15) - 8 off. Tighten evenly to a torque setting of 129±15 Nm (95±10 lb.ft.). Wire lock all bolts using 5P6027 locking wire.
14. Install bearing cone (16).
5. Use a suitable solvent to thoroughly clean and degrease the mating surfaces of drive dog (17) and the housing. Smear the mating surfaces with 2U2856 retaining compound and install the drive dog (17). Apply a coating of 2U2855 thread lock to the screw threads after suitably degreasing. Tighten the screws to a torque setting of 122±15 Nm (90 ± 10 lb.ft.).
16. Install bearing cone (18).
Disassemble Output Transfer Drive
1. Start by:
a) Remove inter axle differential.
2. Remove the differential guard (1) from the output transfer drive housing. The guard is secured by three bolts.
3. Attach bracket (2) to the output transfer drive housing cover (3). Attach a hoist to the bracket and lower onto a prepared surface before further disassembly is started.
NOTE:
- a) The bracket is to be found in the tool box located in the operator's compartment.
- b) The dipstick tube assembly has already been removed in the illustration.
4. Remove all bolts (18 off) securing the housing cover (3). Install two 3/8" UNF eyebolts and attach a hoist.
5. Remove the cover (3) and gasket to reveal the input gear assembly (4) and idler gear assembly (5).
6. Lift out the input gear assembly (4).
7. Lift out the idler gear assembly (5).
Inspect/Replace Worn Parts
1. Inspect all bearing cups (1). If these are damaged or show signs of excessive wear they must be replaced.
2. Inspect all bearing housings (2) to ensure they are in good condition. When installing replacement bearing cups make sure they are seated correctly in the housings.
3. Examine the bearing cones (3) for signs of excessive wear and rough operation. Clean and inspect all gear teeth, shaft splines and bearing diameters for burrs, wear or other damage. Stone away any burrs and replace any parts which are damaged or excessively worn.
4. If, after inspection, further disassembly of the gear assemblies is necessary, carry out the following steps before reassembly:
a) Use a suitable solvent to thoroughly clean and degrease the gear mating surfaces.
b) Apply a coating of 2U2856 retaining compound to the mating surfaces.
c) Early trucks - Tighten the 1/2 UNC bolts (4) to a torque setting of 100 ± 14 Nm(75±10 lb.ft.)
d) Later trucks - Tighten the 5/8 UNF bolts (4) to a torqe setting of 270±14 Nm(200±10lb.ft.)
e) Wire lock the bolts using 5P6027 locking wire.
Assemble Output Transfer Drive
New Parts Required
1. Before starting assembly make sure all parts are clean and free of dirt and foreign material.
2. Position idler gear assembly (1) squarely in bearing cup (2) within the output transfer drive housing. Make sure the smaller diameter gear is uppermost.
3 Position the input gear assembly (3) in bearing cup (4).
4. Make sure both assemblies (1) and (3) are seated squarely within the housing and the gears are meshing correctly.
5. Place gasket (5) in position. Smear both sides of the gasket lightly with clean transmission oil to ensure the gasket stays in position during assembly. Install the cover and fully tighten all bolts.
6. Fasten a hoist and raise the output transfer drive assembly to the vertical position.
7. Install both bearing carriers (7) without shims or 'O' ring seal. Install two equally spaced bolts (8) without washers.
8. While turning the gears by hand, tighten bolts (8) to a torque of 1,5 Nm (13lb. in) Do not overtighten the bolts.
9. Using a thickness gauge, measure the clearance between the cover (6) and bearing carrier (7) at two positions directly opposite each other.
10. Remove the lower bearing carrier (7) and install shims equal to the average measured clearance plus 0.10 mm (0,004 in.).
11. Install the lower bearing carrier (7) with shims, 'O' ring seal and all bolts with washers. Tighten the bolts to 44±7 Nm (32±5 lb.ft.).
12. Remove the carrier cover plate to allow access to the idler gear shaft (8). Check the bearing end clearance with a dial indicator (9). Add or remove shims to obtain 0.10±0.05 mm (0.004±0.002 in.) end clearance.
13. Adjust the bearings on the input gear using the same procedure.
14. Install inter axle differential guard (10).
15. End by:
a) Install inter axle differential.
Remove Inter Axle Differential (Output Transfer Drive Out Of The Truck)
NOTE: The following photographs show the removal procedure with the output transfer drive removed from the truck. The inter axle differential can be removed with the output transfer drive fitted to the truck. In both cases the Removal/Installation procedures are essentially the same.
1. Remove the bolts (1) securing the rear output yoke bearing carrier (2) to the output transfer drive.
2. Use bolts (1) removed in step 1 as forcing bolts to separate carrier (2) from the output transfer drive. Remove the bearing carrier.
3. Remove output shaft (3).
4. Slacken selector shaft (4) by turning anticlockwise until it is fully released. Remove both bolts securing selector shaft boss (5).
5. Remove the selector shaft boss (5) complete with shaft (4) and springs (6).
6. Remove drive dog (7) and selector fork (8).
7. Remove all bolts securing the front bearing carrier (9).
8. Install forcing bolts (removed in step 7) and separate carrier (9) from the differential bearing carrier (10). Remove the carrier.
9. Remove all bolts securing the differential bearing carrier (10) to the output transfer drive.
10 Install forcing bolts (removed in step 9) to separate the differential bearing carrier (10) from the output transfer drive.
11. Remove the differential bearing carrier (10) complete with shim pack (11) and 'O' ring seal (12).
12. Remove the inter axle differential (13). Slide the differential out of the output transfer drive housing on to a protective surface to prevent damage during remval. The differential weighs 70 kg (154 lb.). Remove output shaft (14).
NOTE: Steps 13 to 15 apply to both output yoke bearing carriers.
13. Remove snap ring (15) and thrust washer (16) from the output yoke bearing carrier (17). Remove yoke (18).
14. Remove snap ring (19), bearing (20) and 'O' ring seal (21) from carrier (17).
15. Remove lip seal (22) from carrier (17).
Install Inter Axle Differential (Output Transfer Drive Out Of The Truck)
Parts Required:
1. Soak lip seal (1) in clean transmission oil and install in carrier (2).
NOTE: Steps 1 to 3 apply to both output yoke bearing carriers.
2. Install bearing (3) and snap ring (4) in carrier (2).
3. Install yoke (6) into carrier (2). Install thrust washer (7) and snap ring (8) to retain yoke.
4. Position the differential (9) in the output transfer drive housing. This procedure will be made easier if the front output shaft (10) is installed (button end inward) in the differential as shown. The differential weighs 70 kg (154 lb.).
5. Install bearing cup (11) in the differential bearing carrier (12).
6. Install the differential bearing carrier (12), without shims (13) or 'O' ring seal (14). Install two bolts equally spaced without washers. While turning the gears by hand, tighten the bolts slowly and evenly to 1,5 Nm (13lb. in.). This will take up all end float in the bearings. Do not overtighten.
7. Measure the clearance between the output transfer drive housing and the carrier (12) at two positions directly opposite to each other.
8. Remove the carrier (12) and make up a shim pack (13) whose thickness equals the average clearance plus 0.10 mm (0.004 in.).
9. Install the 'O' ring seal (14) on carrier (12) and put clean transmission oil on it. Install the made up shim pack (13).
10. Install the carrier (12) with made up shim pack and 'O' ring seal. Install and tighten all bolts to a torque setting of 43 ± 7 Nm (32 ± 5 lb.ft.). Check the bearing end clearance with a dial indicator (15). Add or remove shims to obtain 0.10 ± 0.05 mm (0.004 ± 0.002 in) end clearance.
11. Install the output yoke bearing carrier assembly (16). Install all bolts and tighten evenly to a torque setting of 43 ± 7 Nm (32 ± 5 lb.ft.).
12. Position the selector fork (17), with the boss inwards, on drive dog (18) and insert both into the output transfer drive housing as shown.
13. Install 'O' ring seal (19) on the outer diameter and in the bore (20) of the selector boss (21). Put clean transmission oil on the 'O' ring seals. Install shaft (22) and spring (23) in selector boss.
14. Position the selector shaft boss assembly (24) so that the threaded part of the shaft (22) fully engages the threaded bore of the selector fork (17). Turn the shaft clockwise until resistance is felt.
15. Install bolts (25) and tighten to a torque setting of 43 ± 7 Nm (32 ± 5 lb.ft.). Install the rear output shaft (26) - button inwards.
16. Install the yoke bearing carrier assembly (27). Tighten all bolts evenly to a torque setting of 43 ± 7 Nm (32 ± 5 lb.ft.).'
17. Make a final check to ensure selector shaft (22) is fully home, then turn anti-clockwise until the hole in the end of the shaft is horizontal.
Remove Inter Axle Differential (Output Transfer Drive In The Truck)
1. Park the truck on lever ground with the tractor end on full lock to the right to allow access to the centre drive shaft (1) and the differential lock actuator (2). Apply the parking brake (control valve to the PARK position), select Neutral and stop the engine.
2. Remove the cotter pin (3) and clevis pin (4) from the differential lock actuator yoke (5). Remove both bolts (6) securing the actuator and strap the actuator to the truck frame to provide clearance for removal of the output yoke bearing carrier assembly (7).
3. Remove two bolts (8) from each end of the centre drive shaft.
4. Start the engine and move the truck forward slowly (still on full right lock) until the bolts on the opposite side of the drive shaft are accessible. Apply the parking brake, select Neutral and stop the engine.
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Take care when removing the remaining bolts from the drive shaft. It is possible for the gear train to "wind off" - the output yoke may rotate for about 1/2 turn. Keep hands and fingers out during this procedure. |
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5. Remove the remaining bolts (9) from the centre drive shaft (1).
6. Remove the centre drive shaft.
7. Start the engine, release the park brake and slowly turn the truck into the straight ahead position. Stop the engine and apply the parking brake.
8. Use the hand lever (10) on the suspension control valve to fully lower the front suspension.
9. Raise and support the front frame on suitable stands or blocks.
10. Use a suitable jack to raise the front drive axle. Remove both wheels.
11. Support the drive axle using stands or blocks.
12. Remove all bolts securing the sump guard (11). Remove the sump guard.
13. Remove cap (12) from brake fluid reservoir (13). Cover the top of the reservoir with cellophane and refit the cap. This will prevent excessive loss of brake fluid when the system brake hose is disconnected.
NOTE: For trucks fitted with spring brakes it will be necessary to exhaust the air from the system and then disconnect the air lines at the axle housing.
14. Disconnect the brake hose (14) from the left hand wheel brake (15). Plug the hose and cap the connection at the wheel brake.
15. Disconnect the rod (16) from the right hand grease cap (17). Mark the position of the rod on the cap to ensure correct reassembly.
16. Disconnect the remote grease line connections (18) from the suspension pivot pin grease cap and cylinder rod pivot pin.
17. Remove the right and left hand steering cylinder rod pivot pins (19). Retain the bolts, washers and seal faces. Discard the 'O' ring seals. This procedure will permit the steering cylinders to pivot outwards thus allowing removal of the suspension frame clamp bolts.
18. Remove all bolts securing both grease caps (17).
19. Remove grease cap (17) and shims (20). Retain the shims for reassembly.
20. Remove the bolts and washers from both suspension cylinder rod pivot pins (21).
21. Remove the left and right hand pivot pins (21).
NOTE: Do not lose the seal faces from the cylinder rod eye.
22. Remove the drain plug (22) from the output transfer drive and allow the oil to drain into a suitable container (C Truck - 35 litres) (D400 - 105 litres).
23. Position a wheeled stand under the axle/suspension frame assembly. Lower the axle onto the stand using a suitable jack or lift truck. Make sure the assembly is well supported before starting further disassembly.
24. Remove the bolts securing the spider (23) to the front drive axle.
25. Remove the bolts from the suspension frame clamps (24) on both sides of the truck. Remove the clamps.
26. Separate the axle/suspension frame assembly (25) from the front frame (26). Move the assembly well clear of the frame to provide access to the output transfer drive.
27. Remove all bolts securing the spider (23) to the inter axle differential output yoke. Remove the universal joint.
28. End by:
a) Remove the inter axle differential (Refer to Remove Inter Axle Differential - Output Transfer Drive Out of the Truck).
Install Inter Axle Differential (Output Transfer Drive In The Truck)
Parts Required:
The above parts are required in addition to the parts listed under "Install Inter Axle Differential (Output Transfer Drive Out of the Truck)".
1. Start by:
a) Install Inter Axle Differential (Output Transfer Drive Out of the Truck) - steps 1 to 15.
2. Install spider (1) on the inter axle differential output yoke. Fully tighten all bolts (4 off).
3. Position the axle/suspension frame assembly (2) on the frame pivot point (3). The assembly can be positioned by using a suitable moveable stand or lift trucks.
4. Position the suspension frame clamps (4) and install the bolts and washers securing the clamps. Tighten to a torque setting of 870 ± 110 Nm (640 ± 80 lb.ft.).
5. Connect the spider (1) to the drive axle input yoke (5).
NOTE: Make sure the yoke is in alignment with the yoke on the opposite end of the spider.
6. Install the suspension cylinder rod pivot pins (6) using new 'O' ring seals under the rod eye seal faces.
7. Install washer (7), lockwasher (8) and bolt (9) to secure the pivot pins (6) on both sides of the truck.
8. Install grease cap (10) using shims retained in removal procedure. Fully tighten all bolts.
9. Install the steering cylinder rod pivot pins (11) using new 'O' ring seals under the rod eye seal faces. Install washers (12), lockwashers (13) and bolts (14) to secure the pivot pins.
10. Connect the remote grease lines (15) to the suspension pivot pin grease caps (10) and suspension cylinder rod pivot pins (6).
11. Install rod (16) on the right hand grease cap (17).
12. Connect the brake line (18) to the brake assembly (19).
NOTE: On trucks fitted with spring brakes it will be necessary to connect the air lines at the axle housing.
13. Install the sump guard (20).
14. Install the front wheels.
15. Remove the stands supporting the truck.
16. Install the centre drive shaft (21).
NOTE: Make sure the yokes at both ends of the drive shaft are in alignment.
17. Install the differential lock actuator on the frame. Fully tighten bolts (22). Position the actuator shaft (23) on the differential selector shaft. Install clevis pin (24) and secure with cotter pin (25).
18. End by:
a) Service the torque converter screen.
b) Fill the transmission with oil.
c) Fill the brake fluid reservoir and bleed the brakes.
Torque Converter Screen
The torque converter screen should be removed and cleaned if the transmission, torque converter or output transfer drive are disassembled for any reason.
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Do not allow hot oil or components to contact skin. Hot oil and components can cause personal injury. Use all cleaning solutions with care. |
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1. Loosen the bolts holding the cover (1). Allow the oil to drain into a suitable container.
2. Remove the cover.
3. Remove the screen (2) from the housing. Wash in clean non-flammable solvent. Check the condition of the screen and replace if damaged.
4. Inspect the gasket (3) and replace if damaged.
5. Install the screen in the housing.
6. Install the cover.
Transmission Control Linkage Adjustment - D400
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Transmission control linkage adjustment should be made only with the engine OFF. Accidental transmission engagement and sudden truck movement could result in personal injury. |
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Speed Linkage
1. Bracket
2. Bolt
3. Yoke end
4. Nut
5. Seal
6. Cable assembly
7. Nut
8. Washer
9. Pin and ring
10. Seal
11. Spool
1. Move the gearshift lever to select FOURTH speed position. The direction lever should be in the NEUTRAL position.
2. Remove bolts (2) and lockwashers.
3. Loosen nut (7), move seal (5) and washer (8), and unscrew bracket (1) until all are off the threads of cable assembly (6).
4. Lift pin (9) and yoke (3) out of the slot in speed selection spool (11).
5. Pull spool (11) out of the case until its movement is stopped.
6. Hold the spool (11) and install pin (9) in the slot in the spool. If the pin cannot be installed without movement of the spool, make an adjustment to yoke (3). Tighten nut (4).
7. Install bracket (1) on the threads of cable assembly (6) and turn the bracket until it is even with the face of the transmission case.
8. Install the bolts (2) and lockwashers to hold bracket (1) to the transmission case.
9. Install seal (5), washer (8) and nut (7). Tighten nut (7) against bracket (1).
Direction Linkage
1. Bracket
2. Bolt
3. Yoke end
4. Cam
5. Seal
6. Nut
7. Cable Assembly
8. Washer
9. Pin and ring
10. Seal
11. Spool
1. The direction lever must be in the NEUTRAL position.
2. Remove bolts (2) and lockwashers.
3. Loosen nut (6), move seal (5) and washer (8), and unscrew bracket (1) until all are off the threads of cable assembly (7).
4. Lift pin (9) and yoke (3) out of the slot in spool (11).
5. Hold spool (11) and install pin (9) into the slot of the spool. If the pin cannot be installed without movement of the spool, make an adjustment to yoke (3). Tighten cam (4).
6. Install bracket (1) on the threads of cable assembly (7) and turn the bracket until it is even with the face of the transmission case.
7. Install bolts (2) and lockwashers to hold bracket (1) to the transmission case.
8. Install seal (5), washer (8) and nut (6). Tighten nut (6) against bracket (1).
Transmission Control Linkage Adjustment - C Trucks
Transmission Control Group
1. Spool
2. Nut
3. Rod
4. Bolt
5. Ball Joint
6. Cam
7. Detent
8. Nut
9. Rod
10. Nut
11. Spool
12. Rollers
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Do not attempt to adjust the transmission control linkage unless the engine is shut down. Ensure that the battery isolator switch is OFF, remove the key and post a suitable notice to ensure that the engine is not started. If the transmission is accidentally engaged while the linkage is being adjusted the truck may move and cause an accident. |
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Adjustment Procedure for Trucks Fitted with Non-Adjustable Detent
1. Remove the covers from the cam housing and control valve housing.
2. Slacken nut (8) and remove bolt (4).
3. Move the cam (6) until the detent (7) is in the fourth speed notch (illustrated).
4. Loosen nuts (2) and (10) and adjust the rods (3) and (9) until spools (1) and (11) are both in line with face X of the main valve body. The rods must be adjusted such that any free movement of the spools is equal on either side of face X. Tighten nuts (2) and (10).
5. Move the selector lever in the cab to the fourth speed position.
6. Turn the ball joint (5) until the bolt (4) can be installed. Install the bolt (4) and tighten the nut (8).
7 Check that at least 80% of the hole in each of the rollers (12) is visible. Parts must be replaced as necessary to achieve proper adjustment.
8. Install the housing covers using new gaskets if required.
Selector Linkage in Neutral to Show Rollers (12) More Clearly
Adjustable Detent Arrangement
7. Detent
13. Bolt
14. Bolt
15. Block
Adjustment Procedure for Trucks Fitted with Adjustable Detent
(Refer Also To Illustration on Facing Page)
1. Remove the covers from the cam housing and control valve housing.
2. Slacken nut (8) and remove bolt (4).
3. Move the cam (6) until the assembly is in the fourth speed position (illustrated).
4. Slacken bolts (13) and (14) so that the block (15) is free to slide back and forth.
Place the detent (7) in the fourth speed notch in the cam (6).
6. Move the cam assembly so that at least 80% of the hole in each of the two rollers (12) is visible.
7. Tighten bolts (13) and (14).
8. Adjust spools (1) and (11) to equalise end play about face X on the valve body.
9. Move the gear selector lever in the cab to the fourth speed position.
10. Turn the ball joint (5) until the bolt (4) can be installed. Install bolt (4) and tighten the nut (8).
11. Install the housing covers using new gaskets if required.