980G Wheel Loader Power Train Torque Converter - 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: Apply oil to all of the bearings before assembly.

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Illustration 1	g00504278

1. Use Tooling (C) to install sleeve bearing (59) in cover assembly (57). Sleeve bearing (59) must be even with the outside surface of cover assembly (57).
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   Illustration 2	g00504279

2. Install cover assembly (57) to rotating housing (39).
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   Illustration 3	g00503564

3. Install ring seal (58) to rotating housing (39).

4. Install eight bolts (56) and the washers. Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
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   Illustration 4	g00504307

5. Install thrust bearing race (54), thrust bearing (55), and thrust bearing race (54) to cover assembly (57).
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   Illustration 5	g00504312

6. Install retaining ring (53) in turbine hub (51).
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   Illustration 6	g00504313

7. Install converter turbine (50) on turbine hub (51).
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   Illustration 7	g00504315

8. Install twenty bolts (52). Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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   Illustration 8	g00504382

9. Install turbine hub (51) and converter turbine (50) as a unit to rotating housing (39).
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   Illustration 9	g00503538

10. Install two thrust bearing races (49) and the bearing to the hub.
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    Illustration 10	g00504436

11. Use Tooling (C) to install sleeve bearing (48) to carrier assembly (44). Bearing sleeve (48) must be even with the counterbore of carrier assembly (44).
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    Illustration 11	g00504882

12. Install retainer ring (47) in stator (46).
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    Illustration 12	g00504931

13. Position carrier assembly (44) on a wood block.

14. Use proper equipment to handle stator (46). Heat stator (46) to a maximum temperature of 121°C (250°F) for one hour.

15. Install stator (46) on carrier assembly (44).
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    Illustration 13	g00504935

16. Install snap ring (45) in stator (46).
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    Illustration 14	g00505049

17. Install stator (46) and carrier assembly (44) in rotating housing (39).
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    Illustration 15	g00503352

18. Install two thrust bearing races (43) and the thrust bearing to the carrier assembly.
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    Illustration 16	g00503351

19. Position impeller hub (42) on a wood block.

20. Install converter impeller (41) on impeller hub (42).
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    Illustration 17	g00503350

21. Install drive flange (38) on converter impeller (41).
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    Illustration 18	g00503348

22. Install twelve bolts (40). Tighten the bolts to a torque of 80 ± 10 N·m (60 ± 7 lb ft).
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    Illustration 19	g00503345

23. Install drive flange (38) on rotating housing (39). The weight of drive flange (38) is 23 kg (51 lb).

24. Install 36 bolts (37) and the washers. Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
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    Illustration 20	g00505183

25. Install retaining ring (36) in the groove of drive gear (35).
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    Illustration 21	g00505224

26. Use the proper equipment to handle outer bearing race (60). Lower the temperature of outer bearing race (60).

27. Install outer bearing race (60) in drive gear (35). Make sure that outer bearing race (60) makes contact with retaining ring (36).
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    Illustration 22	g00505319

28. Install drive gear (35) on drive flange (38).
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    Illustration 23	g00505349

29. Install twelve bolts (34) and the washers. Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).
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    Illustration 24	g00505352

30. Use the proper equipment to handle inner bearing (33). Heat inner bearing (33) to a maximum temperature of 135°C (275°F). Install inner bearing (33) on bearing carrier (28).
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    Illustration 25	g00505358

31. Install retaining ring (32) in the groove of bearing carrier (28).
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    Illustration 26	g00505359

32. Use the proper equipment to handle ring carrier (31). Heat ring carrier (31) to a maximum temperature of 135°C (275°F). Install ring carrier (31) on bearing carrier (28).
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    Illustration 27	g00505387

33. Install seal ring (30) on ring carrier (31).

34. Install O-ring seal (29) on bearing carrier (28).
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    Illustration 28	g00505395

35. Install bearing carrier (28) in drive flange (38).
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    Illustration 29	g00505423

36. Install retaining ring (27) in carrier assembly (44) in order to hold bearing carrier (28) in place.
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    Illustration 30	g00503312

37. Install two studs (26) in torque converter housing assembly (2). Tighten the studs to a torque of 100 ± 15 N·m (74 ± 11 lb ft).
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    Illustration 31	g00505444

38. Install retaining ring (24) in the groove of idler gear (15).
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    Illustration 32	g00505465

39. Use the proper equipment to handle bearing cup (25). Lower the temperature of bearing cup (25). Install bearing cup (25) in idler gear (15).
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    Illustration 33	g00505470

40. Flip idler gear (15) to the opposite side. Install bearing cup spacer (23) in idler gear (15). The notch in bearing cup spacer (23) must be aligned with retaining ring (24).
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    Illustration 34	g00505479

41. Use the proper equipment to handle bearing cup (22). Lower the temperature of bearing cup (22). Install bearing cup (22) in idler gear (15).
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    Illustration 35	g00505480

42. Install bearing cone (21), bearing cone spacer (20) and bearing cone (19) in idler gear (15).
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    Illustration 36	g00505482

43. Apply clean hydraulic oil on O-ring seal (17). Install O-ring seal (17) on shaft assembly (18).
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    Illustration 37	g00505508

44. Install 1/2" - 13 NC guide pin (61) in shaft assembly (18).

45. Hold transfer gear (15) in position in torque converter housing assembly (2). Install shaft assembly (18).

46. Remove guide pin (61) from shaft assembly (18).
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    Illustration 38	g00505517

47. Install bolt (14) that holds shaft assembly (18) in place in torque converter housing assembly (2). Tighten the bolt to a torque of 120 ± 20 N·m (90 ± 15 lb ft).
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    Illustration 39	g00505572

48. Use the proper equipment to handle bearing cones (12). Heat bearing cones to a maximum temperature of 135°C (275°F). Install a bearing cone (12) on each side of pump drive gear (11).
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    Illustration 40	g00505585

49. Use the proper equipment to handle bearing cup (13). Lower the temperature of bearing cup (13). Install bearing cup (13) in torque converter housing assembly (2).
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    Illustration 41	g00505591

50. Install pump drive gear (11) in torque converter housing assembly (2).
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    Illustration 42	g00505594

51. Use the proper equipment to handle bearing cup (8). Lower the temperature of bearing cup (8). Install bearing cup (8) in pump adapter (6).
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    Illustration 43	g00505623

52. Install shims (9) on pump adapter (6).

53. Apply clean hydraulic oil on O-ring seal (10). Install O-ring seal (10) on pump adapter (6).
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    Illustration 44	g00505666

54. Install two 3/8" - 16 NC guide pins (62) in torque converter housing assembly (2).

55. Install pump adapter (6) on torque converter housing assembly (2).
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    Illustration 45	g00505669

56. Install thirteen bolts (5) and the washers.

57. Use Tooling (B) to check bearing end play. The bearing end play must be 0.15 ± 0.05 mm (.006 ± .002 inch). Add or remove shims in order to get the correct bearing end play.

    Note: If end play is less than 0.10 mm (.004 inch) add additional shims. If end play is greater than 0.20 mm (.008 inch) remove shims.

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    Illustration 46	g00505670

58. Apply clean hydraulic oil on O-ring seal (4). Install O-ring seal (4) on torque converter housing assembly (2).
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    Illustration 47	g01022823

59. Install two 1/2" - 13 NC guide pins (63) in the carrier assembly.

60. Install Tooling (A) to torque converter housing assembly (2), as shown. Attach a hoist and suitable lifting chains to Tooling (A). Use the hoist to carefully install torque converter housing assembly (2) on the torque converter.
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    Illustration 48	g00503225

61. Install eight bolts (1) and the washers to torque converter housing assembly (2). Tighten the bolts to a torque of 120 ± 20 N·m (90 ± 15 lb ft).

End By:

1. Connect the torque converter to the transmission and to the output transfer gears. Refer to Disassembly and Assembly, "Torque Converter to Transmission, Output Transfer Gears - Connect" for the machine that is being serviced.