966 GC Wheel Loader Power Train Output Transfer Gears - Assemble Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, thoroughly clean all parts 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: Check the O-ring seals, the gaskets, and the seals for wear or for damage. Replace the components, if necessary.

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Illustration 1	g02126560

1. Install O-ring seal (36) on drain plug (35).
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   Illustration 2	g02126093

2. Install drain plug (35) on the output transfer gear assembly (2). Tighten drain plug (35) to a torque of 100 ± 10 N·m (74 ± 7 lb ft).
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   Illustration 3	g02126092

3. Make sure that magnet assembly (34) is in position on screen tube assembly (32).

4. Install screen tube assembly (32) in suction screen (33).
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   Illustration 4	g03371917

5. Install screen tube assembly (32).

6. Apply clean oil on O-ring seal (31). Install O-ring seal (31) on the cover. Install gasket (30).
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   Illustration 5	g02126088

7. Install covers (29).
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   Illustration 6	g02128163

8. Install output transfer gear (24) in the output transfer gear assembly (2). The weight of output transfer gear (24) is approximately 23 kg (50 lb).
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   Illustration 7	g02128534

9. Lower the temperature of the bearing cup (26). Install bearing cup (26) in bearing cage (25). Make sure that bearing cup (26) contacts the mating surface.
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   Illustration 8	g02128554

10. Raise the temperature of the bearing cones (28). Install bearing cones (28) on output shaft (17).
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    Illustration 9	g02128893

11. Install bearing cage (25) on output shaft (17).

12. Install bearing cup (26).
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    Illustration 10	g02129893

13. Apply clean oil to O-ring seal (27). Install O-ring seal (27) on bearing cage (25).
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    Illustration 11	g03367145

14. Install Tooling (F) in the output transfer gear assembly (2). Install bearing cage (25) and output shaft (17). Remove Tooling (F).
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    Illustration 12	g02126078

15. Apply clean oil to lip seal (23). Use Tooling (B) to install lip seal (23) in bearing retainer (22).
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    Illustration 13	g02126077

16. Install bearing retainer (22).
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    Illustration 14	g02126076

17. Apply Tooling (H) to the threads of the bolt that secures yoke (21). Install yoke assembly (21) on the output shaft (17) (not shown).
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    Illustration 15	g03569661

18. Raise the temperature of bearing cone (16). Install bearing cone (16) and spacer (15) on output shaft (17).
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    Illustration 16	g02126075

19. Apply clean oil to lip seal (18). Use Tooling (D) to install lip seal (18) in bearing cage assembly (14).

20. Lower the temperature of bearing cup (19). Install bearing cup (19) in bearing cage assembly (14). Make sure that bearing cup (19) contacts the mating surface.

21. Apply clean oil to O-ring seal (20). Install O-ring seal (20) on bearing cage assembly (14).
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    Illustration 17	g03569660

22. Install bearing cage assembly (14) to output transfer gear assembly (2).
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    Illustration 18	g03569658

23. Apply Tooling (H) to the threads of the bolt that secures yoke (13). Install yoke (13) onto output transfer gear assembly (2). Yoke (13) must be installed in phase with yoke (21) (not shown).
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    Illustration 19	g02126063

24. Use a suitable lifting device to reposition output transfer gear assembly (2) on suitable cribbing. The weight of output transfer gear assembly (2) is approximately 222 kg (490 lb).

25. Lower the temperature of bearing cup (12). Install bearing cup (12) in the output transfer gear assembly (2).
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    Illustration 20	g02134334

26. Raise the temperature of bearing cones (11). Install one bearing cone (11) on each side of input transfer gear (10).
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    Illustration 21	g02126059

27. Use a suitable lifting device to install input transfer gear (10). The weight of input transfer gear (10) is approximately 19 kg (42 lb).

28. Install speed sensors (9). Tighten speed sensors (9) to a torque of 37 ± 4 N·m (27 ± 3 lb ft).
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    Illustration 22	g02126058

29. Lower the temperature of bearing cup (7). Install bearing cup (7) in bearing cage assembly (6). Do not install O-ring seal (8) or shims at this time.
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    Illustration 23	g02134593

    Note: The bearing axis must be vertical for correct end play adjustment.

30. Use a 0.038 mm (0.0015 inch) shim or a standard feeler gauge to ensure that the bearing cups and the bearing cones are seated in the housing.

    Note: Do not install the O-ring seal (8) or the shims at this time.

31. Install bearing cage assembly (6). Tighten bolts evenly.

32. Turn input transfer gear (10) for at least three revolutions to seat the bearings.

33. Use a standard feeler gauge to measure the gap between the output transfer gear assembly and bearing cage assembly (6).

34. Add shims between bearing cage assembly (6) and the output transfer gear assembly (2) to obtain 0.10 ± 0.05 mm (0.004 ± 0.002 inch) end play.
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    Illustration 24	g03367173

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    Illustration 25	g03366999

35. Remove bearing cage assembly (6). Install O-ring seal (8) on bearing cage assembly (6). Install bearing cage assembly (6) with the required shims from Step 34.

36. Apply clean oil to the O-ring seal (5). Install O-ring seal (5) on bearing cage assembly (6).
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    Illustration 26	g03367219

37. Use Tooling (G) to measure the bearing end play. If the bearing end play is less than 0.05 mm (0.002 inch), add shims. If the bearing end play is more than 0.15 mm (0.006 inch), remove shims.
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    Illustration 27	g02126022

38. Install cover (4).
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    Illustration 28	g02125904

39. Reposition output transfer gear assembly (2) on suitable cribbing. The weight of output transfer gear assembly (2) is approximately 283 kg (624 lb).

40. Install cover (3) and the gasket.
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    Illustration 29	g03366953

41. Install tube assembly (1).

End By:

1. Connect the output transfer gears to the transmission planetary group.