16M Motor Grader Power Train Transmission - Assemble Caterpillar


Transmission - Assemble
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1.1. Assembly Procedure

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
439-3940  Link Brackets 
386-6033  Lever Puller Hoist 
1P-2420  Transmission Repair Stand 
4C-8156  Lifting Fixture 
FT-2769  Table 
9U-7480  Compressing Tube 
5P-7970 Nut 
8T-4224 Hard Washer 
- Bolt
M13 - 1.25 by 460 mm 
9U-7480  Compressing Tube 
8T-4133 Nut 
8T-4121 Washer 
- Bolt
M10 - 1.5 by 460mm 
189-0408  Shackle As 
3E-3882  Eyebolt 
271-2911  Alignment Tool 
271-2922 Alignment Tool 
9U-7480  Compressing Tube 
6V-8149 Nut 
5P-8245 Hard Washer 
- Bolt
M12- 1.75 by 460 mm 
426-2786  Seal Installer 
8C-8422  Sealant 


NOTICE

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

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.




    Illustration 1g02517381

  1. 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).


    Illustration 2g02517378

  2. Lower the temperature of races (241) and races (240) . Install races (241) and races (240) into housing (54).


    Illustration 3g02517376

  3. Install O-ring seal (239).


    Illustration 4g02517362

  4. Raise the temperature of bearing (238). Install bearing (238). Install retaining ring (237).


    Illustration 5g02517360

  5. Install gear (236).

  6. Install retaining ring (235).


    Illustration 6g02517359

  7. Install retainer (234). Install bearing (233). Install retaining ring (232).


    Illustration 7g02517358

  8. Install gear (231). Install bolts (230). Tighten bolts (230) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).


    Illustration 8g02517437

  9. 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).


    Illustration 9g02517216

  10. Use a suitable lifting device to remove shaft assembly (227). The weight of shaft assembly (227) is approximately 20 kg (44 lb).


    Illustration 10g01391080

  11. 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).


    Illustration 11g01390889

  12. Install O-ring seal (226) and seal ring (225).


    Illustration 12g06082035


    Illustration 13g06085755

  13. 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.



    Illustration 14g01390885

  14. Install piston (223).


    Illustration 15g01390883


    Illustration 16g01390880

  15. Install plates (222) and discs (221).

  16. Install slider (220).

  17. Use Tooling (K) to align plates (222) and discs (221). Install end plate (219). Install retaining ring (218). Remove Tooling (K).


    Illustration 17g06210706

    ------ WARNING! ------

    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.


  18. Install spring (215). Install retainer (217). Use Tooling (J) to compress spring (215). Install retaining ring (216). Remove Tooling (J).


    Illustration 18g01390877

  19. Install thrust washer (214).


    Illustration 19g01390872

  20. Lower the temperature of bearing (213). Install bearing (213) into gear (212).


    Illustration 20g01390871

  21. Install gear (212).


    Illustration 21g01391086

  22. Install thrust washer (211). Install thrust washer (210). Install thrust race (209). Lower the temperature of race (208). Install race (208).


    Illustration 22g01390946

  23. Use a suitable lifting device to turn over clutch assembly (185). The weight of clutch assembly (185) is approximately 68 kg (150 lb).


    Illustration 23g01390689

  24. Install O-ring seal (207) and seal ring (206).


    Illustration 24g06082035


    Illustration 25g06085763

  25. 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.



    Illustration 26g01390686

  26. Install piston (204).


    Illustration 27g01390685


    Illustration 28g01390949

  27. Install plates (203) and discs (202).

  28. Install slider (201).

  29. Use Tooling (K) to align plates (203) and discs (202). Install end plate (200). Install retaining ring (219). Remove Tooling (K).


    Illustration 29g01390682

    ------ WARNING! ------

    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.


  30. Install spring (196). Install retainer (198). Use Tooling (G) to compress spring (196). Install retaining ring (197). Remove Tooling (G).


    Illustration 30g01390680

  31. Install thrust washer (195).


    Illustration 31g01390676

  32. Lower the temperature of bearing sleeves (194). Install bearing sleeves (194) into gear (193).


    Illustration 32g01390672

  33. Install gear (193). Install thrust washer (192).


    Illustration 33g03780804

  34. Install spacer (191).


    Illustration 34g01390668

  35. Install gear (188). Install spacer (187).


    Illustration 35g01391096

  36. Raise the temperature of bearing (186). Install bearing (186) with the radius towards the shaft.


    Illustration 36g01390658

  37. 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).


    Illustration 37g01391099

  38. 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).


    Illustration 38g01391047

  39. Install O-ring seal (180) and seal ring (179).


    Illustration 39g06082035


    Illustration 40g06085771

  40. 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.



    Illustration 41g01390651

  41. Install piston (177).


    Illustration 42g01390647


    Illustration 43g01390646

  42. Install plates (176) and discs (175).

  43. Install slider (174).

  44. Use Tooling (N) to align plates (176) and discs (175). Install end plate (173). Install retaining ring (172).


    Illustration 44g06210699

    ------ WARNING! ------

    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.


  45. Install spring (169). Install retainer (171). Use Tooling (G) to compress spring (169). Install retaining ring (170). Remove Tooling (G).


    Illustration 45g01390641

  46. Install thrust washer (168).


    Illustration 46g01390639

  47. Lower the temperature of bearing (167). Install bearing (167) into gear (166).


    Illustration 47g01390634

  48. Install gear (166).


    Illustration 48g01391104

  49. Install thrust washer (165). Install thrust washer (164). Install thrust race (163). Raise the temperature of race (162). Install race (162).


    Illustration 49g01391110

  50. Use a suitable lifting device to turn over clutch assembly (145). The weight of clutch assembly (145) is approximately 86 kg (190 lb).


    Illustration 50g02407538

  51. Install O-ring seal (161B) and seal ring (161A).


    Illustration 51g06082035


    Illustration 52g06085780

  52. 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.



    Illustration 53g01390627

  53. Install piston (160).


    Illustration 54g01390625


    Illustration 55g01390622

  54. Install plates (159) and discs (158).

  55. Install slider (157).

  56. Use Tooling (N) to align plates (159) and discs (158). Install end plate (156). Install retaining ring (155).


    Illustration 56g01390617

    ------ WARNING! ------

    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.


  57. Install spring (152). Install retainer (154). Use Tooling (G) to compress spring (152). Install retaining ring (153). Remove Tooling (G).


    Illustration 57g01390620

  58. Install thrust washer (151).


    Illustration 58g01390614

  59. Lower the temperature of bearing (150). Install bearing (150) into gear (149).


    Illustration 59g01390612

  60. Install gear (149).


    Illustration 60g01391116

  61. Install thrust washer (148). Install spacer (147). Raise the temperature of bearing (146). Install bearing (146) with the radius towards the shaft.


    Illustration 61g01390604

  62. 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).


    Illustration 62g02521778

  63. Install gear (140D) and spacer (140C). Raise the temperature of bearing (140B). Install bearing (140B). Install seal ring (140A).


    Illustration 63g01391124

  64. 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).


    Illustration 64g01390597

  65. Install O-ring seal (140) and seal ring (139).


    Illustration 65g06082035


    Illustration 66g06085796

  66. 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.



    Illustration 67g01390595

  67. Install piston (137). Install slider (136).


    Illustration 68g01390593

  68. Install plates (135) and discs (134).

  69. Install hub (133).


    Illustration 69g01390592

  70. Install end plate (132). Install retaining ring (131).


    Illustration 70g06210695

    ------ WARNING! ------

    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.


  71. Install spring (128). Install retainer (130). Use Tooling (J) to compress spring (128). Install retaining ring (129). Remove Tooling (J).


    Illustration 71g01390588

  72. Install thrust washer (127).


    Illustration 72g01390586

  73. Lower the temperature of bearing sleeves (126). Install bearing sleeves (126) into gear (125).


    Illustration 73g01390584

  74. Install gear (125).


    Illustration 74g01390583

  75. Install thrust washer (124). Install spacer (123).


    Illustration 75g01390582

  76. Install gear (122). Install spacer (121).


    Illustration 76g01391134

  77. Raise the temperature of bearing (120). Install bearing (120) with the radius towards the shaft.


    Illustration 77g01391136

  78. Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 113 kg (250 lb).


    Illustration 78g01390578

  79. Install O-ring seal (119) and seal ring (118).


    Illustration 79g06082035


    Illustration 80g06497026

  80. 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.



    Illustration 81g01390572

  81. Install piston (115). Install slider (114).


    Illustration 82g01390565

  82. Install plates (113) and discs (112).

  83. Install hub (111).


    Illustration 83g01390562

  84. Install end plate (110). Install retaining ring (109).


    Illustration 84g01390555

    ------ WARNING! ------

    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.


  85. Install spring (106). Install retainer (108). Use Tooling (G) to compress spring (106). Install retaining ring (107). Remove Tooling (G).


    Illustration 85g01390554

  86. Lower the temperature of bearing sleeve (105). Install bearing sleeve (105) into gear (104).


    Illustration 86g01390549

  87. Install gear (104). Install thrust washer (103).


    Illustration 87g01390547

  88. Install gear (102). Install thrust washer (101).


    Illustration 88g01391152

  89. Raise the temperature of bearing (100). Install bearing (100) with the radius towards the shaft.


    Illustration 89g01391164

  90. 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).


    Illustration 90g01390540

  91. Install O-ring seal (99) and seal ring (98).


    Illustration 91g01390430

  92. 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.



    Illustration 92g01390428

  93. Install piston (96).


    Illustration 93g01390426


    Illustration 94g01390425

  94. Install plates (95) and discs (94).

  95. Use Tooling (N) to align plates (95) and discs (94). Install end plate (93). Install retaining ring (92).


    Illustration 95g06210691

    ------ WARNING! ------

    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.


  96. Install spring (89). Install retainer (91). Use Tooling (M) to compress spring (89). Install retaining ring (90). Remove Tooling (M).


    Illustration 96g01390420

  97. Install thrust washer (88).


    Illustration 97g01390419

  98. Install gear (86). Lower the temperature of bearing sleeves (87). Install bearing sleeves (87).


    Illustration 98g01390414

  99. Install gear (86).

  100. Install thrust washer (85). Install spacer (84).


    Illustration 99g01391166

  101. Raise the temperature of bearing (83). Install bearing (83).


    Illustration 100g01391168

  102. Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 104 kg (230 lb).


    Illustration 101g01390409

  103. Install O-ring seal (82) and seal ring (81).


    Illustration 102g06082035


    Illustration 103g06085833

  104. 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.



    Illustration 104g01390403

  105. Install piston (79).


    Illustration 105g01390400


    Illustration 106g01390395

  106. Install plates (78) and discs (77).

  107. Use Tooling (N) to align plates (78) and discs (77). Install end plate (76). Install retaining ring (75).


    Illustration 107g01390392

  108. Install slider (74).


    Illustration 108g01390389

    ------ WARNING! ------

    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.


  109. Install spring (71). Install retainer (73). Use Tooling (G) to compress spring (71). Install retaining ring (72). Remove Tooling (G).


    Illustration 109g01390383

  110. Install thrust washer (70).


    Illustration 110g01390381

  111. Lower the temperature of bearing sleeves (69). Install bearing sleeves (69) into gear (68).


    Illustration 111g01390377

  112. Install gear (68). Install thrust washer (67).


    Illustration 112g01391176

  113. Install rotor (66). Raise the temperature of bearing (65). Install bearing (65) with the radius towards the shaft.


    Illustration 113g01390368

  114. 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).


    Illustration 114g01390365

  115. 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).


    Illustration 115g02517501

  116. 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).

  117. Install bolts (52). Tighten bolts (52) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).


    Illustration 116g01391196

  118. Install seal rings (183) and install O-ring seals (184) onto seal carrier (182).


    Illustration 117g01391201

  119. 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.



    Illustration 118g01391205

  120. Install O-ring seals (144) and install seal rings (143) onto seal carrier (142).


    Illustration 119g01391212

  121. 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.



    Illustration 120g01391216

  122. Install seal rings (61) and install O-ring seals (62) onto seal carrier (60). Repeat this step for seal carrier (58).


    Illustration 121g01391217

  123. 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.



    Illustration 122g01390360

  124. Install speed sensor (50) and speed sensor (51). Install bolts (49).


    Illustration 123g01390359

  125. Install cover (48).


    Illustration 124g01390356

  126. Install speed sensor (47) and speed sensor (46). Install bolts (45).


    Illustration 125g01390355

  127. Install speed sensor (44). Install bolt (43).


    Illustration 126g02517380

  128. Install covers (243) and covers (242) onto housing (54).


    Illustration 127g01390322

  129. 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).


    Illustration 128g01390352

  130. Install hub (42). Install retaining ring (41).


    Illustration 129g01390351

  131. Install O-ring seals (40) and O-ring seal (39).

  132. Install discs (37) and plates (38).


    Illustration 130g01390349

  133. Install seal (36).


    Illustration 131g01390345

  134. Install O-ring seal (35), O-ring seal (34), O-ring seal (33), O-ring seal (32), and O-ring seal (31).


    Illustration 132g01390343

  135. Install solenoid (30). Install pressure sensor (29) and the O-ring seal.


    Illustration 133g01390342

  136. 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 of 55 ± 10 N·m (41 ± 7 lb ft).


    Illustration 134g01390339

  137. Connect harness assembly (26) and harness assembly (25).


    Illustration 135g01390334

  138. Install piston (22).


    Illustration 136g01390331

  139. Install spring discs (21).


    Illustration 137g01390329

  140. Install O-ring seal (20).


    Illustration 138g01390327

  141. Install lip seal (19).


    Illustration 139g01390323

    ------ WARNING! ------

    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.


  142. Install spring plate (18). Install bolts (17). Tighten bolts (17) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).


    Illustration 140g01391235


    Illustration 141g01390304

  143. 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.


    Illustration 142g01390318

  144. Install spacers (16) and control module (15). Install bolts (14).


    Illustration 143g01390315

  145. Install O-ring seal (13). Install cup (12). Install retaining ring (11).


    Illustration 144g01390309

  146. Install yoke assembly (10).


    Illustration 145g01390308

  147. Position filter base (9) and install bolts (8). Connect harness assembly (7).


    Illustration 146g01390307

  148. Install tube assembly (6). Install tube assembly (5). Install tube assembly (4). Install hose assembly (3). Install clip (2).

End By:

  1. Install the transmission. Refer to Disassembly and Assembly, "Transmission - Install".

Information System: