Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 439-3940 | Link Brackets | 4 |
B | 386-6033 | Lever Puller Hoist | 1 |
C | 1P-2420 | Transmission Repair Stand | 1 |
D | 4C-8156 | Lifting Fixture | 1 |
E | FT-2769 | Table | 1 |
G | 9U-7480 | Compressing Tube | 1 |
5P-7970 | Nut | 1 | |
8T-4224 | Hard Washer | 1 | |
- | Bolt
M13 - 1.25 by 460 mm |
1 | |
J | 9U-7480 | Compressing Tube | 1 |
8T-4133 | Nut | 1 | |
8T-4121 | Washer | 1 | |
- | Bolt
M10 - 1.5 by 460mm |
1 | |
K | 189-0408 | Shackle As | 1 |
L | 3E-3882 | Eyebolt | 1 |
N | 271-2911 | Alignment Tool | 1 |
271-2922 | Alignment Tool | 1 | |
M | 9U-7480 | Compressing Tube | 1 |
6V-8149 | Nut | 1 | |
5P-8245 | Hard Washer | 1 | |
- | Bolt
M12- 1.75 by 460 mm |
1 | |
P | 426-2786 | Seal Installer | 1 |
R | 8C-8422 | Sealant | - |
NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
Note: Lubricate all seal rings and O-ring seals prior to assembly.
Note: Inspect the O-ring seals. Replace O-ring seals that are worn or damaged.
Note: Remove old anaerobic sealant from the bottom of the blind tapped holes in housing (251) before assembling.
NOTICE |
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Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
- Lower the temperature of race (246) and race (245). Install race (246) and race (245) into housing (247). Lower the temperature of bearings (244). Install bearings (244) into housing (247).
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Illustration 2 g02517378 - Lower the temperature of races (241) and races (240) . Install races (241) and races (240) into housing (54).
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Illustration 3 g02517376 - Install O-ring seal (239).
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Illustration 4 g02517362 - Raise the temperature of bearing (238). Install bearing (238). Install retaining ring (237).
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Illustration 5 g02517360 - Install gear (236).
- Install retaining ring (235).
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Illustration 6 g02517359 - Install retainer (234). Install bearing (233). Install retaining ring (232).
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Illustration 7 g02517358 - Install gear (231). Install bolts (230). Tighten bolts (230) to a torque of
28 ± 7 N·m (21 ± 5 lb ft) .Show/hide tableIllustration 8 g02517437 - Use a suitable lifting device to position shaft assembly (227) onto Tooling (E). The weight of shaft assembly (227) is approximately
20 kg (44 lb) . Use suitable blocking to support shaft assembly (227). Install gear (229). Raise the temperature of race (228). Install race (228).Show/hide tableIllustration 9 g02517216 - Use a suitable lifting device to remove shaft assembly (227). The weight of shaft assembly (227) is approximately
20 kg (44 lb) .Show/hide tableIllustration 10 g01391080 - Use a suitable lifting device to position clutch assembly (185) onto Tooling (E). The weight of clutch assembly (185) is approximately
35 kg (77 lb) .Show/hide tableIllustration 11 g01390889 - Install O-ring seal (226) and seal ring (225).
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Illustration 12 g06082035 Show/hide tableIllustration 13 g06085755 - Install piston seal ring (224). Lubricate piston and seal groove with the oil being sealed. Use Tooling (P) to install the O-ring (242) and seal ring (243) as shown.
Note: Do not overstretch the seals.
Note: Assure that the seal rings are properly seated in the groove of the piston.
Show/hide tableIllustration 14 g01390885 - Install piston (223).
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Illustration 15 g01390883 Show/hide tableIllustration 16 g01390880 - Install plates (222) and discs (221).
- Install slider (220).
- Use Tooling (K) to align plates (222) and discs (221). Install end plate (219). Install retaining ring (218). Remove Tooling (K).
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Illustration 17 g06210706 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (215). Install retainer (217). Use Tooling (J) to compress spring (215). Install retaining ring (216). Remove Tooling (J).
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Illustration 18 g01390877 - Install thrust washer (214).
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Illustration 19 g01390872 - Lower the temperature of bearing (213). Install bearing (213) into gear (212).
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Illustration 20 g01390871 - Install gear (212).
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Illustration 21 g01391086 - Install thrust washer (211). Install thrust washer (210). Install thrust race (209). Lower the temperature of race (208). Install race (208).
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Illustration 22 g01390946 - Use a suitable lifting device to turn over clutch assembly (185). The weight of clutch assembly (185) is approximately
68 kg (150 lb) .Show/hide tableIllustration 23 g01390689 - Install O-ring seal (207) and seal ring (206).
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Illustration 24 g06082035 Show/hide tableIllustration 25 g06085763 - Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (244) and seal ring (205) as shown.
Note: Do not overstretch the seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
Show/hide tableIllustration 26 g01390686 - Install piston (204).
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Illustration 27 g01390685 Show/hide tableIllustration 28 g01390949 - Install plates (203) and discs (202).
- Install slider (201).
- Use Tooling (K) to align plates (203) and discs (202). Install end plate (200). Install retaining ring (219). Remove Tooling (K).
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Illustration 29 g01390682 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (196). Install retainer (198). Use Tooling (G) to compress spring (196). Install retaining ring (197). Remove Tooling (G).
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Illustration 30 g01390680 - Install thrust washer (195).
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Illustration 31 g01390676 - Lower the temperature of bearing sleeves (194). Install bearing sleeves (194) into gear (193).
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Illustration 32 g01390672 - Install gear (193). Install thrust washer (192).
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Illustration 33 g03780804 - Install spacer (191).
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Illustration 34 g01390668 - Install gear (188). Install spacer (187).
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Illustration 35 g01391096 - Raise the temperature of bearing (186). Install bearing (186) with the radius towards the shaft.
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Illustration 36 g01390658 - Use Tooling (K), Tooling (L), and a suitable lifting device to install clutch assembly (185). The weight of clutch assembly (185) is approximately
68 kg (150 lb) .Show/hide tableIllustration 37 g01391099 - Use a suitable lifting device to position clutch assembly (145) onto Tooling (E). The weight of clutch assembly (145) is approximately
34 kg (75 lb) .Show/hide tableIllustration 38 g01391047 - Install O-ring seal (180) and seal ring (179).
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Illustration 39 g06082035 Show/hide tableIllustration 40 g06085771 - Install piston seal ring (178). Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring (245) and seal ring (246) as shown.
Note: Do not overstretch the seals.
Note: Assure that the seal rings are properly seated in the groove of the piston.
Show/hide tableIllustration 41 g01390651 - Install piston (177).
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Illustration 42 g01390647 Show/hide tableIllustration 43 g01390646 - Install plates (176) and discs (175).
- Install slider (174).
- Use Tooling (N) to align plates (176) and discs (175). Install end plate (173). Install retaining ring (172).
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Illustration 44 g06210699 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (169). Install retainer (171). Use Tooling (G) to compress spring (169). Install retaining ring (170). Remove Tooling (G).
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Illustration 45 g01390641 - Install thrust washer (168).
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Illustration 46 g01390639 - Lower the temperature of bearing (167). Install bearing (167) into gear (166).
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Illustration 47 g01390634 - Install gear (166).
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Illustration 48 g01391104 - Install thrust washer (165). Install thrust washer (164). Install thrust race (163). Raise the temperature of race (162). Install race (162).
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Illustration 49 g01391110 - Use a suitable lifting device to turn over clutch assembly (145). The weight of clutch assembly (145) is approximately
86 kg (190 lb) .Show/hide tableIllustration 50 g02407538 - Install O-ring seal (161B) and seal ring (161A).
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Illustration 51 g06082035 Show/hide tableIllustration 52 g06085780 - Install piston seal rings (161). Lubricate piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring (247) and ring seal (248) as shown.
Note: Do not overstretch the seals.
Note: Assure that the ring seals are properly seated in the groove of the piston.
Show/hide tableIllustration 53 g01390627 - Install piston (160).
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Illustration 54 g01390625 Show/hide tableIllustration 55 g01390622 - Install plates (159) and discs (158).
- Install slider (157).
- Use Tooling (N) to align plates (159) and discs (158). Install end plate (156). Install retaining ring (155).
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Illustration 56 g01390617 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (152). Install retainer (154). Use Tooling (G) to compress spring (152). Install retaining ring (153). Remove Tooling (G).
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Illustration 57 g01390620 - Install thrust washer (151).
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Illustration 58 g01390614 - Lower the temperature of bearing (150). Install bearing (150) into gear (149).
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Illustration 59 g01390612 - Install gear (149).
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Illustration 60 g01391116 - Install thrust washer (148). Install spacer (147). Raise the temperature of bearing (146). Install bearing (146) with the radius towards the shaft.
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Illustration 61 g01390604 - Use Tooling (K), Tooling (L), and a suitable lifting device to install clutch assembly (145). The weight of clutch assembly (145) is approximately
86 kg (190 lb) .Show/hide tableIllustration 62 g02521778 - Install gear (140D) and spacer (140C). Raise the temperature of bearing (140B). Install bearing (140B). Install seal ring (140A).
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Illustration 63 g01391124 - Use a suitable lifting device to position clutch assembly (64) onto Tooling (E). The weight of clutch assembly (64) is approximately
34 kg (75 lb) .Show/hide tableIllustration 64 g01390597 - Install O-ring seal (140) and seal ring (139).
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Illustration 65 g06082035 Show/hide tableIllustration 66 g06085796 - Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (138) and seal ring (249) as shown.
Note: Do not overstretch seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
Show/hide tableIllustration 67 g01390595 - Install piston (137). Install slider (136).
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Illustration 68 g01390593 - Install plates (135) and discs (134).
- Install hub (133).
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Illustration 69 g01390592 - Install end plate (132). Install retaining ring (131).
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Illustration 70 g06210695 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (128). Install retainer (130). Use Tooling (J) to compress spring (128). Install retaining ring (129). Remove Tooling (J).
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Illustration 71 g01390588 - Install thrust washer (127).
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Illustration 72 g01390586 - Lower the temperature of bearing sleeves (126). Install bearing sleeves (126) into gear (125).
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Illustration 73 g01390584 - Install gear (125).
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Illustration 74 g01390583 - Install thrust washer (124). Install spacer (123).
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Illustration 75 g01390582 - Install gear (122). Install spacer (121).
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Illustration 76 g01391134 - Raise the temperature of bearing (120). Install bearing (120) with the radius towards the shaft.
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Illustration 77 g01391136 - Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately
113 kg (250 lb) .Show/hide tableIllustration 78 g01390578 - Install O-ring seal (119) and seal ring (118).
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Illustration 79 g06082035 Show/hide tableIllustration 80 g06497026 - Lubricate the piston (115) and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (250) and seal ring (251) as shown.
Note: Do not overstretch seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
Show/hide tableIllustration 81 g01390572 - Install piston (115). Install slider (114).
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Illustration 82 g01390565 - Install plates (113) and discs (112).
- Install hub (111).
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Illustration 83 g01390562 - Install end plate (110). Install retaining ring (109).
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Illustration 84 g01390555 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (106). Install retainer (108). Use Tooling (G) to compress spring (106). Install retaining ring (107). Remove Tooling (G).
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Illustration 85 g01390554 - Lower the temperature of bearing sleeve (105). Install bearing sleeve (105) into gear (104).
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Illustration 86 g01390549 - Install gear (104). Install thrust washer (103).
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Illustration 87 g01390547 - Install gear (102). Install thrust washer (101).
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Illustration 88 g01391152 - Raise the temperature of bearing (100). Install bearing (100) with the radius towards the shaft.
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Illustration 89 g01391164 - Use a suitable lifting device to position clutch assembly (64) onto Tooling (E). The weight of clutch assembly (64) is approximately
38 kg (84 lb) .Show/hide tableIllustration 90 g01390540 - Install O-ring seal (99) and seal ring (98).
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Illustration 91 g01390430 - Lubricate the piston and seal groove with the oil being sealed. Install seal ring (97).
Note: Do not over stretch seal ring.
Note: Assure that the seal ring is properly seated in the groove of the piston.
Show/hide tableIllustration 92 g01390428 - Install piston (96).
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Illustration 93 g01390426 Show/hide tableIllustration 94 g01390425 - Install plates (95) and discs (94).
- Use Tooling (N) to align plates (95) and discs (94). Install end plate (93). Install retaining ring (92).
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Illustration 95 g06210691 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (89). Install retainer (91). Use Tooling (M) to compress spring (89). Install retaining ring (90). Remove Tooling (M).
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Illustration 96 g01390420 - Install thrust washer (88).
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Illustration 97 g01390419 - Install gear (86). Lower the temperature of bearing sleeves (87). Install bearing sleeves (87).
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Illustration 98 g01390414 - Install gear (86).
- Install thrust washer (85). Install spacer (84).
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Illustration 99 g01391166 - Raise the temperature of bearing (83). Install bearing (83).
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Illustration 100 g01391168 - Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately
104 kg (230 lb) .Show/hide tableIllustration 101 g01390409 - Install O-ring seal (82) and seal ring (81).
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Illustration 102 g06082035 Show/hide tableIllustration 103 g06085833 - Lubricate the piston and seal groove with the oil being sealed. Use Tooling (P) to install O-ring seal (80) and seal ring (252) as shown.
Note: Do not overstretch seals.
Note: Assure that the seal ring is properly seated in the groove of the piston.
Show/hide tableIllustration 104 g01390403 - Install piston (79).
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Illustration 105 g01390400 Show/hide tableIllustration 106 g01390395 - Install plates (78) and discs (77).
- Use Tooling (N) to align plates (78) and discs (77). Install end plate (76). Install retaining ring (75).
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Illustration 107 g01390392 - Install slider (74).
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Illustration 108 g01390389 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring (71). Install retainer (73). Use Tooling (G) to compress spring (71). Install retaining ring (72). Remove Tooling (G).
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Illustration 109 g01390383 - Install thrust washer (70).
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Illustration 110 g01390381 - Lower the temperature of bearing sleeves (69). Install bearing sleeves (69) into gear (68).
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Illustration 111 g01390377 - Install gear (68). Install thrust washer (67).
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Illustration 112 g01391176 - Install rotor (66). Raise the temperature of bearing (65). Install bearing (65) with the radius towards the shaft.
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Illustration 113 g01390368 - Use Tooling (D) and a suitable lifting device to install clutch assembly (64) and clutch assembly (63). The weight of clutch assembly (64) and clutch assembly (63) is approximately
204 kg (450 lb) .Show/hide tableIllustration 114 g01390365 - Install tube assembly (56). Install bolts (55). Tighten bolts (55) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) . Install O-ring seal (54).Show/hide tableIllustration 115 g02517501 - Apply Tooling (R) onto the mating surface of housing (247). Use Tooling (A), Tooling (B), and a suitable lifting device to install housing (53). The weight of housing (53) is approximately
261 kg (575 lb) . - Install bolts (52). Tighten bolts (52) to a torque of
55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 116 g01391196 - Install seal rings (183) and install O-ring seals (184) onto seal carrier (182).
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Illustration 117 g01391201 - Install seal carrier (182). Install bolts (181).
Note: Ensure that the spring pin that is in the seal carrier is aligned with the hole that is in the end of the shaft assembly.
Show/hide tableIllustration 118 g01391205 - Install O-ring seals (144) and install seal rings (143) onto seal carrier (142).
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Illustration 119 g01391212 - Install seal carrier (142). Install bolts (141).
Note: Ensure that the spring pin that is in the seal carrier is aligned with the hole that is in the end of the shaft assembly.
Show/hide tableIllustration 120 g01391216 - Install seal rings (61) and install O-ring seals (62) onto seal carrier (60). Repeat this step for seal carrier (58).
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Illustration 121 g01391217 - Install seal carrier (58) and install bolts (57). Install seal carrier (60) and install bolts (59).
Note: Ensure that the spring pin that is in the seal carrier is aligned with the hole that is in the end of the shaft assembly.
Show/hide tableIllustration 122 g01390360 - Install speed sensor (50) and speed sensor (51). Install bolts (49).
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Illustration 123 g01390359 - Install cover (48).
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Illustration 124 g01390356 - Install speed sensor (47) and speed sensor (46). Install bolts (45).
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Illustration 125 g01390355 - Install speed sensor (44). Install bolt (43).
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Illustration 126 g02517380 - Install covers (243) and covers (242) onto housing (54).
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Illustration 127 g01390322 - Use Tooling (A), Tooling (B), and a suitable lifting device to position transmission (1) with the output shaft upward. The weight of transmission (1) is approximately
1043 kg (2300 lb) .Show/hide tableIllustration 128 g01390352 - Install hub (42). Install retaining ring (41).
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Illustration 129 g01390351 - Install O-ring seals (40) and O-ring seal (39).
- Install discs (37) and plates (38).
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Illustration 130 g01390349 - Install seal (36).
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Illustration 131 g01390345 - Install O-ring seal (35), O-ring seal (34), O-ring seal (33), O-ring seal (32), and O-ring seal (31).
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Illustration 132 g01390343 - Install solenoid (30). Install pressure sensor (29) and the O-ring seal.
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Illustration 133 g01390342 - Use two people to install housing (28). The weight of housing (28) is approximately
27 kg (60 lb) . Install bolts (27). Tighten bolts (27) to a torque of55 ± 10 N·m (41 ± 7 lb ft) .Show/hide tableIllustration 134 g01390339 - Connect harness assembly (26) and harness assembly (25).
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Illustration 135 g01390334 - Install piston (22).
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Illustration 136 g01390331 - Install spring discs (21).
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Illustration 137 g01390329 - Install O-ring seal (20).
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Illustration 138 g01390327 - Install lip seal (19).
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Illustration 139 g01390323 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install spring plate (18). Install bolts (17). Tighten bolts (17) to a torque of
100 ± 20 N·m (74 ± 15 lb ft) .Show/hide tableIllustration 140 g01391235 Show/hide tableIllustration 141 g01390304 - Use Tooling (A), Tooling (B), and a suitable lifting device to remove transmission (1) from Tooling (C). The weight of transmission (1) is approximately
1043 kg (2300 lb) . Position transmission (1) onto suitable cribbing.Show/hide tableIllustration 142 g01390318 - Install spacers (16) and control module (15). Install bolts (14).
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Illustration 143 g01390315 - Install O-ring seal (13). Install cup (12). Install retaining ring (11).
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Illustration 144 g01390309 - Install yoke assembly (10).
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Illustration 145 g01390308 - Position filter base (9) and install bolts (8). Connect harness assembly (7).
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Illustration 146 g01390307 - Install tube assembly (6). Install tube assembly (5). Install tube assembly (4). Install hose assembly (3). Install clip (2).
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Illustration 1 | g02517381 |
End By:
- Install the transmission. Refer to Disassembly and Assembly, "Transmission - Install".