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


Transmission Planetary - Assemble - Heavy Duty
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1.1. Assembly Procedure

Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
138-7575  Link Bracket 
1P-7407  Eyebolt 
FT-0833  Clamp 
1P-1863  Retaining Ring Pliers 
1P-0520  Driver Gp 
1P-0510  Driver Gp 
1P-1861  Retaining Ring Pliers 
  3/8 - 16 in Bolt 

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 1g00397059
Correct method for compressing the rings


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


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


    Illustration 4g01887226

  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.


    Illustration 5g01887224

  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.


    Illustration 6g03811404

  3. Install piston (140).


    Illustration 7g01909917

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


    Illustration 8g01909936

  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.


    Illustration 9g01889333

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


    Illustration 10g01887219

  7. Install shaft assembly (134) in shaft assembly (133).


    Illustration 11g01887218

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


    Illustration 12g01887217

  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.


    Illustration 13g01887216

  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).


    Illustration 14g01887215

  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.


    Illustration 15g01887213

  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).


    Illustration 16g01887212

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


    Illustration 17g06109942

  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).


    Illustration 18g01887209

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


    Illustration 19g01888539

  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).


    Illustration 20g01887207

  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.


    Illustration 21g01887203

  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).


    Illustration 22g01910043

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


    Illustration 23g01887200

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


    Illustration 24g03811387

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


    Illustration 25g01887199

  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.


    Illustration 26g01887198

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


    Illustration 27g01887197

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


    Illustration 28g01887195

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


    Illustration 29g01887093

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


    Illustration 30g01887014

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


    Illustration 31g01886953

  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).


    Illustration 32g01886934

  39. Install gear (83) on the shaft assembly.


    Illustration 33g01888354

  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).


    Illustration 34g01888333

  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.


    Illustration 35g01886900

  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).


    Illustration 36g01886898

  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).


    Illustration 37g01886897

  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.


    Illustration 38g01886896

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


    Illustration 39g01888273


    Illustration 40g01886861

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


    Illustration 41g01886860

  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).


    Illustration 42g01910593

  53. Install ring gear (50) and gear (51).


    Illustration 43g01910598

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


    Illustration 44g01910614

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


    Illustration 45g01910619

  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).


    Illustration 46g01910634

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


    Illustration 47g01910637

  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).


    Illustration 48g01910640

  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.


    Illustration 49g01910655

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

    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).


    Illustration 50g01910673

  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.


    Illustration 51g01910733

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


    Illustration 52g01886846

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


    Illustration 53g01886845

  66. Install clutch piston (39) in the clutch housing.


    Illustration 54g01886843

  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).


    Illustration 55g01886841

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


    Illustration 56g01886839

  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.


    Illustration 57g01886838

  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).


    Illustration 58g01886836

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


    Illustration 59g01886835

  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).


    Illustration 60g01886833


    Illustration 61g01886826

  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.


    Illustration 62g01886819

  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).


    Illustration 63g01886818

  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.


    Illustration 64g01886816

  83. Install gear (15) on the manifold assembly.


    Illustration 65g01886815

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

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


    Illustration 66g01886814

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

  87. Install piston (11) in clutch housing (9).


    Illustration 67g01886813


    Illustration 68g01886812

  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.


    Illustration 69g01915294

  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).


    Illustration 70g01915279

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


    Illustration 71g01915255

  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).


    Illustration 72g01915234

  94. Connect tube assembly (1).


    Illustration 73g01915213

  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".

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