Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 1P-2420 | Transmission Repair Stand | 1 |
B | 439-3938 | Link Bracket | 2 |
D | 439-3940 | Link Bracket | 2 |
F | - | Loctite High Flex From-In-Place Gasket | - |
G | 126-3994 | Duo-Cone Seal Installer | 1 |
H | - | Loctite C5-A Anti-Seize Lubricant | - |
J | 6V-4876 | Lubricant | - |
- Install the final drive sprocket if the sprocket was removed from the main housing.
- Refer to Disassembly and Assembly, "Final Drive Sprocket - Remove and Install".
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Illustration 1 g00708215 - Apply Tooling (H) to the outer diameter of the bearings.
- Install bearings (32) and (33) in main housing (18) with a suitable press.
- Make sure that bearing (32) and bearing (33) contact the counter bore in the main housing.
- Use the following procedure to preload the bearings and determine the correct thickness of shims.
- Fasten Tooling (D) and a suitable lifting device to main housing (18). Install the main housing on the motor housing.
- Put the main housing and the motor housing in a suitable press.
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Illustration 3 g00709278 (a) Bearing surface
(b) Housing surface - Use a suitable press and a spacer to apply a load of
4000 kg (8819 lb) on the bearings. Rotate the housing to seat the bearings. - Reduce the load on the bearings to
1000 ± 100 kg (2205 ± 221 lb) . - Use a depth micrometer to measure the step length between the bearing surface and the housing surface. Take measurements at several different locations around the housing. Compute the average of the measured dimensions and record the number. Call this Dimension (Y).
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Illustration 4 g00709276 - Use a depth micrometer to measure the step length of gear (26). Take measurements at several different locations around the gear. Compute the average of the measured dimensions and record the number. Call this Dimension (X).
- The thickness of the shims is equal to (X − Y) ±
0.05 mm (0.002 inch) .Note: Use no more than two shims. If two shims are required, install the thinner shim next to the gear.
- Remove the main housing from the motor housing.
Show/hide tableIllustration 2 g00713058 Show/hide tableIllustration 5 g01021370 - Use Tooling (G) to install Duo-Cone seal (31) in main housing (18). Refer to Disassembly and Assembly, "Duo-Cone Conventional Seals - Install".
Note: The rubber seals and all surfaces that contact the seals must be clean and dry. After installation of the seals, apply Tooling (J) on the contact surfaces of the metal seals.
Show/hide tableIllustration 6 g01021371 - Use Tooling (G) to install Duo-Cone seal (29) in motor housing (28).
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Illustration 7 g00708214 - Apply Tooling (H) to the surfaces that contact pins (30).
- Install alignment pins (30).
Note: Do not damage the Duo-Cone seals in the main housing or in the motor housing during the assembly of the two components. After installation of the main housing on the motor housing, there will be a small gap between the components. The gap is caused by the Duo-Cone seals. This gap will be eliminated during installation of gear (26).
Show/hide tableIllustration 8 g00713058 - Fasten Tooling (D) and a suitable lifting device to main housing (18). Install the main housing on the motor housing.
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Illustration 9 g00708211 - Install shims (27) that were determined in Step 6g in the main housing.
Note: If two shims are required, install the thinner shim next to the gear.
Show/hide tableIllustration 10 g00708187 - Install gear (26).
- Install bolts (25) in gear (26). Install the bolts in an even pattern until the gear is seated against the bearing. Tighten bolts (25) in a crisscross pattern.
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Illustration 11 g00708186 - Install O-ring seal (24) to main housing (18).
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Illustration 12 g00708175 - Assemble carrier assembly (15), as follows.
- Install bearings (22) in planetary gear (23).
- Install thrust washers (21) and planetary gear (23) in the carrier assembly.
- Use a deburring tool to remove the metal burr from the openings in the carrier. Install planetary shaft (19) in the carrier assembly.
- Drive spring pin (20) into planetary shaft (19) with a hammer and a punch.
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Illustration 14 g00513451 - Orient the split in spring pin (20) vertically to the carrier. Align the split in the spring pin to the top or to the bottom. Make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately
1.50 mm (0.059 inch) from the outside diameter of the spring pin hole.
Show/hide tableIllustration 13 g00708220 - Repeat Steps 16a through 16e to install the remaining planetary gears in the carrier assembly.
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Illustration 15 g00708172 - Install a lifting sling through the middle of carrier assembly (15). Fasten a
12.7 mm (0.50 inch) shackle to the suitable lifting device. - Install carrier assembly (15) on the final drive. The weight of carrier assembly (15) is approximately
39 kg (85 lb) . - Remove the shackle and the suitable lifting device.
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Illustration 16 g00713148 - Apply Tooling (F) to the mating surface of ring gear (17b).
- Install ring gear (17a) on ring gear (17b).
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Illustration 17 g00708184 Typical Example - Fasten a suitable lifting device to ring gears (17), as shown. Install the ring gears to main housing (18). The weight of ring gears (17) is approximately
45 kg (100 lb) .Show/hide tableIllustration 18 g00708325 - Install spacer (16) in the carrier assembly.
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Illustration 19 g00708162 - Install sun gear (14) in carrier assembly (15).
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Illustration 20 g01304883 Show/hide tableIllustration 21 g00708218 - Assemble carrier assembly (7), as follows.
- Install bearing (12) in planetary gear (13).
- Install thrust washers (11) and planetary gear (13) in the carrier assembly.
- Install planetary shaft (9) in the carrier assembly.
- Drive spring pin (10) into planetary shaft (9) with a hammer and a punch.
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Illustration 22 g00513451 - Orient the split in spring pin (10) vertically to the carrier. Align the split in the spring pin to the top or to the bottom. Make a stake mark on each side of the spring pin hole in the carrier. Each stake mark should be approximately
1.50 mm (0.059 inch) from the outside diameter of the spring pin hole.
- Repeat Steps 26a through 26e to install the remaining planetary gears in the carrier assembly.
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Illustration 23 g00708092 - Install carrier assembly (7) in the ring gear. The weight of carrier assembly (7) is approximately
14 kg (30 lb) . - Install sun gear (8) in carrier assembly (7).
- Install spacer (6) in carrier assembly (7).
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Illustration 24 g00708235 - Install new O-ring seals (5) on plugs (4) that were in the cover.
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Illustration 25 g00708091 - Install plugs (4) in cover (2). Tighten plugs (4) to a torque of
80 ± 10 N·m (59 ± 7 lb ft) . - Install thrust plate (3) in cover (2).
- Apply Tooling (F) to the mating surface of the ring gear.
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Illustration 26 g00708090 - Fasten Tooling (B) and a suitable lifting device to cover (2), as shown. The weight of cover (2) is approximately
32 kg (70 lb) . Install cover (2). - Remove Tooling (B) and install the setscrews in cover (2).
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Illustration 27 g00708089 - Install bolts (1) and the washers that hold the cover in position. Tighten bolts (1) in a crisscross pattern.
- Remove the final drive from Tooling (A). The combined weight of the final drive and final drive sprocket is approximately
310 kg (683 lb) .
Note: Cleanliness is an important factor. Before assembly, all parts should be cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. All disassembly and all assembly procedures must be performed on a clean work surface and in a clean hydraulic area. Keep cleaned parts covered and protected at all times.
Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the assembly procedure.
Note: Apply a light film of hydraulic oil to all components before assembly.
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- Install the final drive.