415F2 Industrial Loader Power Train Axle Housing (Service Brakes, Differential and Bevel Gear) - Assemble Caterpillar


Axle Housing (Service Brakes, Differential and Bevel Gear) - Assemble
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1.1. Assembly Procedure

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
220-8428  Spanner Wrench 
220-8430  Pinion Wrench 
202-7965  Adjusting Tool Gp 
1P-0520  Driver Gp 
235-2790  Pinion Setting Tool 
235-2792  Differential Setting Tool 
6V-2012  Depth Micrometer 
Loctite 270 
Loctite Anaerobic Gasket Flange 
8T-5096  Dial Indicator Gp 


    Illustration 1g06048316

  1. Lower the temperature of bearing cups (61). Use Tooling (E) to install bearing cups (61) into the center housing.


    Illustration 2g06048362

  2. Install bearing cones (54) and (59) along with Tooling (F).


    Illustration 3g06048654

  3. Align the location marks that were made during the removal procedure. Position brake cylinder assembly (27) and temporarily install bolts (28). Repeat for the opposite side.


    Illustration 4g03784062

  4. Install Tooling (G) into the center housing. Make sure that Tooling (G) is inserted into both brake cylinders.


    Illustration 5g03784067


    Illustration 6g03784071

  5. Use Tooling (H) to measure Distance (A). Distance (B) equals 145 mm (5.7 inch). Distance (C) equals 50 mm (2.0 inch). Use the following formula to calculate Measurement (X): A + C - Bmm = X. Record Measurement (X).


    Illustration 7g06048369

  6. Measurement (V) is stamped on the head of pinion shaft (56). Use the following formula to calculate Measurement (S): X - V (Stamped on Pinion Head) = S.

  7. Among the available list of shims, choose the shim with the thickness of Measurement (S).


    Illustration 8g06048663

  8. Remove Tooling (G). Remove brake cylinder assemblies (27). Remove the nut and the washer from Tooling (F) and remove Tooling (F). Remove bearing cones (54) and (59).


    Illustration 9g06048389

  9. Install the suitable shim (55) onto pinion shaft (56). Install shim (55) with the chamfer against the gear. Raise the temperature of bearing cone (54) and install bearing cone (54) onto pinion shaft (56). Seat bearing cone (54) firmly against shim (55).


    Illustration 10g06048399

  10. Install washers (57) and collapsible spacer (58) onto pinion shaft (56).


    Illustration 11g06048406

  11. Install pinion shaft (56) into the center housing. Raise the temperature of bearing cone (59) and install bearing cone (59) onto pinion shaft (56).

  12. Install the lock washer and the ring nut on pinion shaft (56).


    Illustration 12g06047672

  13. Use Tooling (A) and Tooling (B) to tighten locknut (52). Use Tooling (B) with a dial type torque wrench to set the rotating torque. Tighten lock nut (52) to achieve a rotating torque of 4.13 N-m to 4.46 N·m (36.6 lb in to 39.5 lb in).


    Illustration 13g03281998

  14. Use a suitable hammer and a punch and stake ring nut (32) into the keyway groove.


    Illustration 14g03652883

  15. Install washer (52), O-ring seal (49). Install seal ring (53) to a depth of 7.5 ± 0.5 mm (0.295 ± 0.020 inch) from the face of housing.

    Note: Seal ring (53) is to be installed after the rolling torque has been set.

  16. Install yoke (50) and retaining ring (51).


    Illustration 15g03652894

  17. Install thrust washer (37) and sun gears (35). Install thrust washers (38), spider gears (34), and shafts (36) into differential housings (33) and (39).

  18. Raise the temperature of bearing cones (32) and (40). Install bearing cones (32) and (40).


    Illustration 16g06048739

  19. Install bevel gear (31) onto the differential housing. Apply Tooling (J) to the threads of bolts (30). Install bolts (30). Tighten bolts (30) to a torque of 180 N·m (133 lb ft).


    Illustration 17g06048777

    Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.

  20. Apply a thin coat of grease onto O-ring seals (21) and (22). Install the O-ring seals onto brake piston (23).


    Illustration 18g03262499

  21. Install shaft (20), and cam (15).


    Illustration 19g03259668

  22. Install cam, using the alignment marks made while disassembling cam (15) with the pin (16).


    Illustration 20g03262498

  23. Install O-ring seal (19).


    Illustration 21g03259666


    Illustration 22g03262497


    Illustration 23g03262496

  24. Install spacer (11) and washer (12).

  25. Install steel ball (18). Install shaft screw (17).


    Illustration 24g03259667

  26. Install bracket (14) and bolts (13).


    Illustration 25g03259658

  27. Install lever (8) using the previous alignment mark on the lever (8) and shaft (9).


    Illustration 26g03259652

  28. Install adjusting screw (5) and tighten lock nut (4).


    Illustration 27g03259655

  29. Install bolt (6) and washer (7).


    Illustration 28g06048784

  30. Install brake piston (23) into brake cylinder assembly (27). Make sure that the holes on brake piston (23) align with the holes in brake cylinder assembly (27). Make sure that the brake piston (23) is installed all the way to the bottom of brake cylinder assembly (27). If necessary, tap brake piston (23) with a rubber mallet to install brake cylinder assembly (27) completely to the bottom.


    Illustration 29g06048794

    ------ 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.


  31. Install springs (24) and the bolts. Install bolts (25). Tighten bolts (25) to a torque of 13 N·m (115 lb in). Tighten springs and bolts (24) to a torque of 13 N·m (115 lb in).


    Illustration 30g06048833

  32. Position brake cylinder assembly (27) on a flat surface. Use Tooling (E) to install bearing cup (48).


    Illustration 31g06045860

  33. Use Tooling (C) and install spanner nut (45) into brake cylinder assembly (27).


    Illustration 32g06048881

  34. Apply Tooling (K) to the mating surfaces of the center housing and the left brake cylinder assembly (27). Align the location marks that were made during the removal procedure. Position brake cylinder assembly (27) onto the opposite side of the bevel gear in the center housing. Install bolts (28). Tighten bolts (28) to a torque of 79 N·m (58 lb ft).


    Illustration 33g06047649

    ------ 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.


    Note: Check the O-ring seals for wear or for damage. If necessary, replace the O-ring seals.

  35. Position fork (68) into the center housing. Install rod (69), spring (70), bushing (71), retaining ring (72), O-ring seals (73), piston (74), O-ring seal (75), and cover (76). Apply Tooling (G) to the threads of bolts (77) and install bolts (77). Install retaining ring (67), washer (66), spring (65), O-ring seal (64), and cover (63). Apply Tooling (J) to the threads of bolts (62) and install bolts (62). Tighten bolts (62) and (77) to a torque of 27 N·m (239+ lb in).


    Illustration 34g01029529

  36. Install the differential into the left side of the center housing.


    Illustration 35g06048917

  37. Apply Tooling (K) to the mating surfaces of the center housing and the right brake cylinder assembly (27). Align the location marks that were made during the removal procedure. Position brake cylinder assembly (27) onto the center housing and install bolts (28). Tighten bolts (28) to a torque of 79 N·m (58 lb ft). Use Tooling (A) and install spanner nut (45).


    Illustration 36g01029534

  38. Oscillate the pinion shaft while using Tooling (A) to advance the spanner nuts until there is slight backlash with no end play.


    Illustration 37g01038165

    Note: Typical example.

  39. Install a dial type torque wrench onto the pinion shaft. Measure the total rotating torque. Use Table 2 to determine the total rotating torque (TRT).

    Table 2
    PINION BEARINGS AND DIFFERENTIAL BEARINGS PRELOAD TABLE 
    BEVEL GEAR RATIO  No. of PINION TEETH  No. of BEVEL TEETH  ALL PRELOAD MUST BE MEASURED WITH PINION SEAL 
    11 32 
    REFERENCE DIA.  44.6 mm (1.76 inch) 
    PINION BEARING PRELOAD  TOTAL PRELOAD (PINION BEARING PRELOAD + BEVEL GEAR BEARINGS PRELOAD 
    TORQUE  MINIMUM TORQUE  MAXIMUM TORQUE 
    4.13 N·m (36.50 lb in)  4.68 N·m (41.39 lb in)  4.95 N·m (43.83 lb in) 
    4.13 N·m (36.56 lb in)  4.68 N·m (41.42 lb in)  4.96 N·m (43.86 lb in) 
    4.15 N·m (36.73 lb in)  4.70 N·m (41.60 lb in)  4.975 N·m (44.03 lb in) 
    4.20 N·m (37.17 lb in)  4.75 N·m (42.04 lb in)  5.03 N·m (44.48 lb in) 
    4.25 N·m (37.62 lb in)  4.800 N·m (42.48 lb in)  5.08 N·m (44.92 lb in) 
    4.30 N·m (38.06 lb in)  4.85 N·m (42.93 lb in)  5.125 N·m (45.36 lb in) 
    4.35N·m (38.50 lb in)  4.90 N·m (43.37 lb in)  5.18 N·m (45.80 lb in) 
    4.40 N·m (38.94 lb in)  4.95 N·m (43.81 lb in)  5.23 N·m (46.25 lb in) 
    4.46 N·m (39.47 lb in)  5.0 N·m (44.34 lb in)  5.29 N·m (46.78 lb in) 

  40. If, the total rotating torque (TRT) is less than the specified amount tighten both spanner nuts equally. If the total rotating torque (TRT) is greater than the specified amount, loosen both spanner nuts equally. Always maintain slight backlash.


    Illustration 38g03784185

    Note: Typical example.

  41. Mount Tooling (L) onto the center housing. Measure the backlash between the pinion and the bevel gear. The proper backlash setting is 0.180 mm to 0.230 mm (0.007 inch to 0.009 inch).


    Illustration 39g01449257

  42. If the backlash is not within the specification, retract one spanner nut and advance the opposite spanner nut equally order to maintain the bearing preload. If the backlash is less than the specified amount, move the bevel gear in Direction (A). If the backlash is greater than the specified amount, move the bevel gear in Direction (B).


    Illustration 40g06048995

  43. Install retainer (46) and bolt (47) into both brake cylinder assemblies (27). Tighten bolts (47) to a torque of 13 N·m (115 lb in).


    Illustration 41g03642506

    Note: There is a raised shoulder on brake hub (3). Ensure that the raised shoulder on the brake hub is positioned toward the axle housing.

  44. Place drive plates (1) between brake disc (2). Make sure holes in brake discs (2) are in alignment for cooling purposes.

End By:

  1. Install the axle housing.

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