980H Wheel Loader Power Train Transmission Planetary - Assemble - Heavy Duty Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly 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.

Note: Use the correct method to make the new rings ready for installation. Place your hands on each end of the ring and expand the ends by each other. Keep the ring in a circular shape to ensure an even bend fully around the ring. The notches in the ends of the rings must contact each other. The ring will damage the edge of the bore if the ring is not installed correctly. The notches must be fully engaged.

Illustration 1	g00397059
Correct method for compressing the rings

Illustration 2	g00397061
The ends of the ring must contact the inner notches (bottom half of the above illustration).

Illustration 3	g00397157
Do not use this method to make new rings ready for installation.

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Illustration 4	g01887226

1. Use Tooling (G) to install bearing (144) in the clutch housing. Install the bearing with the notch in the UPWARD position. Use Tooling (J) to install retaining ring (143) in the groove of the clutch housing.
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   Illustration 5	g01887224

2. Install seals (141) and (142) on the clutch piston so that the oil grooves are facing toward the inside of the clutch housing. Apply clean transmission oil on the seal rings.
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   Illustration 6	g03811404

3. Install piston (140).
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   Illustration 7	g01909917

4. Use Tooling (H) to install bearing (138) in the end of the shaft assembly.
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   Illustration 8	g01909936

5. Raise the temperature of seal carrier (137) to a maximum temperature of 149 °C (300 °F). Install seal carrier (137) on the shaft assembly.
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   Illustration 9	g01889333

6. Install bearing (136). Use Tooling (J) to install retaining ring (135) onto the shaft assembly.
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   Illustration 10	g01887219

7. Install shaft assembly (134) in shaft assembly (133).
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   Illustration 11	g01887218

8. Install spiral lockring (132) that holds the shaft in position.
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   Illustration 12	g01887217

9. Put the shaft assembly in position on suitable blocks, as shown. Install gear (129) on the shaft assembly.

10. Install seals (130) and (131) on the seal carrier. Put a small amount of SAE 30 oil on the seals.
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    Illustration 13	g01887216

11. Install bearings (121) and (125) in gears (122) and (126).

12. Position thrust discs (120), (123), (124), and (127) on each side of the gears.

13. Position gears (122) and (126) in the carrier and install shaft (128).
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    Illustration 14	g01887215

14. Use a hammer and a punch to install spring pin (119) that holds the shaft in the carrier assembly. Make sure that spring pin (119) is flush with the counterbore in the carrier.

15. Repeat Steps 11 through 14 for the installation of the remaining gears.
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    Illustration 15	g01887213

16. Use Tooling (G) to install bearing (117). Install bearing (117) with the notch in the UPWARD position. Install spiral lockring (116) in the carrier.

17. Install seal rings (118). Apply clean transmission oil on seal rings (118).
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    Illustration 16	g01887212

18. Install retainer ring (115) in the carrier. Compress retainer ring (115) to install gear (114).
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    Illustration 17	g06109942

19. Use two people to install carrier assembly (113) on the shaft assembly. Make sure that the notch in the carrier bearing is in alignment with the dowel in the shaft assembly. Install seal ring (145).
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    Illustration 18	g01887209

20. Install gear (111) and spacer (112) on the shaft assembly.
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    Illustration 19	g01888539

21. Install bearing (108) in gear (107).

22. Place thrust discs (106) and (109) on each side of gear (107).

23. Position gear (107) in the carrier. Install shaft (110).
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    Illustration 20	g01887207

24. Use a hammer and a punch to install the spring pin (105) that holds shaft (110) in the carrier assembly. Make sure that spring pin (105) is flush with the counterbore in the carrier.

25. Repeat Steps 21 through 24 for the installation of the remaining gears.
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    Illustration 21	g01887203

26. Use Tooling (G) to install bearing (102) in the carrier. Install bearing with the notch in the DOWNWARD position. Install seals (103) and (104) and spiral lockring (101).
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    Illustration 22	g01910043

27. Install carrier assembly (100) on the shaft assembly (99). Align the notch in the bearing with the dowel in the shaft.
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    Illustration 23	g01887200

28. Use Tooling (E) to install retaining ring (98).
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    Illustration 24	g03811387

29. Position the retaining ring on to output shaft assembly (97). Install gear (139).
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    Illustration 25	g01887199

30. Attach Tooling (C) and a suitable lifting device to output shaft assembly (97). The weight of output shaft assembly (97) and the carrier is approximately 90 kg (200 lb).

31. Put the clutch housing in position on suitable blocks, as shown. Install shaft assembly and carriers in the clutch housing. Make sure that the notch in the bearing is in alignment with the dowel in the carrier assembly.
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    Illustration 26	g01887198

32. Start with a friction disc and install friction discs (95) and clutch plates (96) in the housing.
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    Illustration 27	g01887197

33. Install plate assembly (94) on the housing. Install gear assembly (93).
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    Illustration 28	g01887195

34. Start with a friction disc and install friction discs (91) and clutch plates (92).
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    Illustration 29	g01887093

35. Apply clean transmission oil on seals (89) and (90) and install seal (89) and (90) on the clutch piston.
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    Illustration 30	g01887014

36. Install piston (88) in the No. 2 clutch housing.
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    Illustration 31	g01886953

37. Install springs (85).

38. Use Tooling (D) to hold the piston in clutch housing (84). Attach Tooling (B) and a suitable lifting device to clutch housing (84). Install clutch housing (84). Install bolts (86) that hold the No. 1 housing and No. 2 clutch housing (84) together. Install dowels (87).
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    Illustration 32	g01886934

39. Install gear (83) on the shaft assembly.
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    Illustration 33	g01888354

40. Install bearing (80) in gear (79).

41. Position thrust discs (78) and (81) on each side of gear (79).

42. Position gear (79) in the carrier. Install shaft (82).
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    Illustration 34	g01888333

43. Use a hammer and a punch to install spring pin (77) that holds shaft (82) in the carrier assembly. Make sure that spring pin (77) is flush with the counterbore in the carrier assembly.

44. Repeat Steps 40 through 43 for the installation of the remaining gears.
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    Illustration 35	g01886900

45. Use Tooling (G) to install the bearing (76) in the carrier. Install bearing with the notch in the UPWARD position. Install spiral lockring (75).
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    Illustration 36	g01886898

46. Compress the retaining ring and install gear (74).

47. Install the carrier on hub (73). Make sure that the notch in the bearing is in alignment with the dowel on hub (73). Use Tooling (E) to install retaining ring (72) on hub (73).
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    Illustration 37	g01886897

48. Install Tooling (B) and a suitable lifting device on carrier (71). The weight of carrier (71) is approximately 26 kg (58 lb). Install carrier (71). Use Tooling (E) to install retaining ring (70) on the shaft assembly.
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    Illustration 38	g01886896

49. Start with a friction disc and install friction discs (68) and clutch plates (69).
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    Illustration 39	g01888273

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    Illustration 40	g01886861

50. Install seals (66) and (67) on piston (65). Apply clean transmission oil to the seals. Install piston (65) in the housing.
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    Illustration 41	g01886860

51. Position springs (64).

52. Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to clutch housing (63). The weight of clutch housing (63) is approximately 38 kg (85 lb). Install clutch housing (63).
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    Illustration 42	g01910593

53. Install ring gear (50) and gear (51).
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    Illustration 43	g01910598

54. Place housing assembly (55) in position on gear (51).
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    Illustration 44	g01910614

55. Start with a friction disc and install five friction discs (53) and four clutch plates (54) in housing (55).
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    Illustration 45	g01910619

56. If the ring carrier was removed from the housing assembly, heat a new ring carrier to a maximum temperature of 149 °C (300 °F). Install ring carrier (47). Install pin (49).
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    Illustration 46	g01910634

57. Install seal rings (48). Apply clean transmission oil to seal rings (48).
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    Illustration 47	g01910637

58. Install seals (61) and (62) on piston (60). Apply clean transmission oil to seals (61) and (62).

59. Install piston (60) in reaction plate (56).
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    Illustration 48	g01910640

60. Install springs (59):

    1. Install the first spring (59) with the outside diameter in contact with the housing assembly.

    2. Install the next two springs (59) with the outside diameter of the springs in contact with each other, as shown.

61. Install plate (57) on the springs. Make sure that the holes in the plate, and the springs are in alignment with the holes in the housing assembly.
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    Illustration 49	g01910655

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

62. Install Tooling (K) in the housing assembly, as shown. Compress the springs until spiral lockring (58) can be installed on the housing assembly. Release the pressure on the springs and remove Tooling (K).
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    Illustration 50	g01910673

63. Install reaction plate (56) on the clutch housing (55). Install bolts (52) that secure the clutch housing (55). Install retainer ring (45) on the shaft assembly.
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    Illustration 51	g01910733

64. Start with a friction disc and install friction discs (43) and clutch plate (42) over dowels (44).
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    Illustration 52	g01886846

65. Install seals (40) and (41) on the clutch piston. Apply clean transmission oil on the seal rings.
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    Illustration 53	g01886845

66. Install clutch piston (39) in the clutch housing.
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    Illustration 54	g01886843

67. Install springs (38) in the clutch housing.

68. Use Tooling (D) to hold the piston in the clutch housing (37). Attach Tooling (B) and a suitable lifting device to clutch housing (31). The weight of clutch housing (37) is approximately 25 kg (55 lb). Install clutch housing (31).
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    Illustration 55	g01886841

69. Install bolts (36) that secure the clutch housing.
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    Illustration 56	g01886839

70. Use Tooling (G) to install bearing (35) in the manifold assembly. Install bearing with the notch in the DOWNWARD position.

71. Install retaining ring (34) in the manifold.
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    Illustration 57	g01886838

72. Install O-ring seal (33) on the manifold assembly (32). Apply clean transmission oil to O-ring seal (33).

73. Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of manifold assembly (32) is approximately 72 kg (160 lb).
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    Illustration 58	g01886836

74. Install bolts (31) that hold the manifold assembly to the clutch housing.
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    Illustration 59	g01886835

75. Install the O-ring seal (30) on the manifold assembly. Apply clean transmission oil to O-ring seal (30).

76. Install gear (28) and retaining ring (29).
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    Illustration 60	g01886833

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    Illustration 61	g01886826

77. Install bearings (24) and (26) in gear (25).

78. Position thrust discs (23) and (27) on each side of the gear (25).

79. Put gears (25) in position in the carrier. Install planetary shafts (21). Make sure that the holes in planetary shafts (21) are in alignment with the holes in the carrier. Install spring pin (22). Make sure that spring pins (22) are flush with the counterbore in the carrier.

80. Repeat Steps 77 through 79 for the installation of the remaining gears.
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    Illustration 62	g01886819

81. Put slinger (20) in position in the carrier. Install locks (18) and bolts (19) that hold the slinger (20) in position. Bend the tabs on locks (18).
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    Illustration 63	g01886818

82. Put carrier assembly (17) in position on the shaft assembly. Install the spacer on the carrier. Use Tooling (E) to install retaining ring (16) on the shaft assembly.
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    Illustration 64	g01886816

83. Install gear (15) on the manifold assembly.
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    Illustration 65	g01886815

84. Install dowels (14) in the manifold assembly.

85. Start with a friction disc and install friction discs (12) and clutch plates (13).
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    Illustration 66	g01886814

86. Install seals (10) on the piston. Apply clean transmission oil to seals (10).

87. Install piston (11) in clutch housing (9).
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    Illustration 67	g01886813

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    Illustration 68	g01886812

88. Install springs (8). Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to the housing. The weight of clutch housing (9) is approximately 32 kg (70 lb).

89. Install clutch housing (9). Install bolts (7) that secure the planetary group.
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    Illustration 69	g01915294

90. Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of planetary group (5) is approximately 565 kg (1250 lb). Install planetary group (5) into transmission case (6).
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    Illustration 70	g01915279

91. Install tubes (4) and the O-ring seals.
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    Illustration 71	g01915255

92. Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The weight of modulating valve assembly (2) is approximately 43 kg (95 lb).

93. Install bolts (3).
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    Illustration 72	g01915234

94. Connect tube assembly (1).
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    Illustration 73	g01915213

95. Remove the transmission assembly from Tooling (A).

End By:

1. Connect the transmission and the output transfer gears. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Connect".