980H Wheel Loader Power Train Torque Converter (Freewheel Stator) - Assemble Caterpillar

Assembly Procedure

Note: Cleanliness is an important factor. Before assembly, 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	g01112937

1. Use Tooling (H) to install sleeve bearing (62) in cover assembly (60) . Sleeve bearing (62) must be even with the outside surface of cover assembly (60) .

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Illustration 2	g03337064

2. Install ring seal (61) to rotating housing (36) .

3. Install cover assembly (60) to rotating housing (36) .

4. Install bolts (59) and the washers to cover assembly (60) . Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).

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Illustration 3	g00870744

5. Install races (57) and thrust bearing (58) to cover assembly (60) .

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Illustration 4	g00870748

6. Install retaining ring (56) in turbine hub (54) .

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Illustration 5	g00870755

7. Install turbine (53) on hub (54) .

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Illustration 6	g00870757

8. Install bolts (55) and the washers to turbine (53) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

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Illustration 7	g00870759

9. Install hub (54) and turbine (53) as a unit to rotating housing (36) .

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Illustration 8	g00870760

10. Install thrust bearing race (52) and the bearing to the turbine hub (54) .

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Illustration 9	g01112941

11. Use Tooling (H) and a hydraulic press in order to install sleeve bearing (51) to carrier assembly (41) . Install thrust bearing (50) to carrier assembly (41) .

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Illustration 10	g01112915

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Illustration 11	g01112913

12. Use Tooling (H) and a hydraulic press in order to install freewheel cam (47) to stator (42) .

13. Install plate (49) to stator (42) . Install retaining ring (48) to stator (42) .

Note: If necessary, heat stator (42) to a maximum temperature of 135 °C (275 °F). Install the cam with the IMPELLER SIDE facing downward. Continue with the installation until freewheel cam (47) contacts the retaining ring (not shown).

14. Install stator (42) to carrier assembly (41) . Install freewheel springs (46) and freewheel rollers (45) to freewheel cam (47) . Always install new freewheel springs (46) and freewheel rollers (45) . Install freewheel springs (46) with the maximum number of loops in freewheel springs (46) to the outside of freewheel cam (47) . Use the orientation of stator (42) in Illustration 11 in reference to the following statement: Stator (42) should turn freely in the clockwise direction. Stator (42) should not turn freely in the counterclockwise direction.

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Illustration 12	g00870421

15. Install plate (44) to stator (42) . Install snap ring (43) to stator (42) .

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Illustration 13	g00870422

16. Install carrier assembly (41) and stator (42) as a unit to rotating housing (36) .

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Illustration 14	g00870762

17. Install thrust bearing (40) and race (40A) (not shown) to the carrier assembly (41) .

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Illustration 15	g00870994

18. Position impeller hub (39) on a wood block.

19. Install impeller (38) on impeller hub (39) .

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Illustration 16	g00870995

20. Install drive flange (35) on impeller (38) .

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Illustration 17	g00871000

21. Install bolts (37) on drive flange (35) . Tighten the bolts to a torque of 80 ± 10 N·m (60 ± 7 lb ft).

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Illustration 18	g00871001

22. Install drive flange (35) on rotating housing (36) . The weight of drive flange (35) is approximately 23 kg (51 lb).

23. Install bolts (34) and the washers to drive flange (35) . Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).

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Illustration 19	g00871003

24. Install retaining ring (33) in the groove of drive gear (32) .

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Illustration 20	g00870829

25. Use the proper equipment to handle outer bearing race (32A) . Lower the temperature of outer bearing race (32A) .

26. Install outer bearing race (32A) in drive gear (32) . Make sure that outer bearing race (32A) contact retaining ring (33) .

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Illustration 21	g00870763

27. Install drive gear (32) on drive flange (35) .

28. Install bolts (31) and the washers on drive gear (32) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

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Illustration 22	g00871006

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

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Illustration 23	g00871007

30. Install retaining ring (29) in the groove of bearing carrier (25) .

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Illustration 24	g00871009

31. Use the proper equipment to handle ring carrier (28) . Heat ring carrier (28) to a maximum temperature of 135 °C (275 °F). Install ring carrier (28) on bearing carrier (25) .

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Illustration 25	g00871012

32. Install seal ring (27) on ring carrier (28) .

33. Install O-ring seal (26) on bearing carrier (25) .

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Illustration 26	g00871014

34. Install bearing carrier (25) in drive flange (35) .

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Illustration 27	g00871015

35. Install retaining ring (24) and bearing carrier (25) on carrier assembly (28) .

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Illustration 28	g00872709

36. Install studs (23) 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 29	g00872711

37. Install retaining ring (21) in the groove of idler gear (13) .

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Illustration 30	g00872713

38. Use the proper equipment to handle bearing cup (22) . Lower the temperature of bearing cup (22) . Install bearing cup (22) in idler gear (13) .

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Illustration 31	g00872715

39. Flip idler gear (13) to the opposite side. Install bearing cup spacer (20) in idler gear (13) . The notch in bearing cup spacer (20) must be aligned with retaining ring (21) .

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Illustration 32	g00872716

40. Use the proper equipment to handle bearing cup (19) . Lower the temperature of bearing cup (19) . Install bearing cup (19) in idler gear (13) .

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Illustration 33	g00872718

41. Install bearing cone (16) , bearing cone spacer (17) , and bearing cone (18) in idler gear (13) .

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Illustration 34	g01112903

42. Apply clean hydraulic oil on O-ring seal (15) . Install O-ring seal (15) on shaft assembly (14) .

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Illustration 35	g01112954

43. Install Tooling (K) in shaft assembly (14) .

44. Hold idler gear (13) in position in torque converter housing assembly (2) . Install shaft assembly (15) .

45. Remove Tooling (K) from shaft assembly (14) .

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Illustration 36	g01112970

46. Install bolt (12) that holds shaft assembly (14) 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 37	g00872724

47. Use the proper equipment to handle bearing cones (10) . Heat bearing cones to a maximum temperature of 135 °C (275 °F). Install a bearing cone (10) on each side of pump drive gear (9) .

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Illustration 38	g00872801

48. Use the proper equipment to handle bearing cup (11) . Lower the temperature of bearing cup (11) . Install bearing cup (11) in torque converter housing assembly (2) .

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Illustration 39	g00872727

49. Install pump drive gear (9) in torque converter housing assembly (2) .

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Illustration 40	g00872729

50. Use the proper equipment to handle bearing cup (6) . Lower the temperature of bearing cup (6) .

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Illustration 41	g00871319

51. Apply clean hydraulic oil on O-ring seal (8) .

52. Install bearing cup (6) , O-ring seal (8) , and shims (7) on pump adapter (5) .

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Illustration 42	g01112978

53. Install Tooling (J) in torque converter housing assembly (2) .

54. Install pump adapter (5) on torque converter housing assembly (2) .

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Illustration 43	g01112982

55. Install bolts (4) and the washers on pump adapter (5) and torque converter housing assembly (2) .

56. Use Tooling (G) to check bearing end play. The bearing end play must be 0.15 ± 0.05 mm (0.006 ± 0.002 inch). Add or remove shims in order to get the correct bearing end play.

    Note: If end play is less than 0.10 mm (0.004 inch) add additional shims. If end play is greater than 0.20 mm (0.008 inch) remove shims.

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Illustration 44	g00872732

57. Apply clean hydraulic oil on O-ring seal (3) . Install O-ring seal (3) on torque converter housing assembly (2) .

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Illustration 45	g01112984

58. Install Tooling (J) in the carrier assembly.

59. Install Tooling (A) to torque converter housing assembly (2) , as shown. Attach a suitable lifting device to Tooling (A) . The weight of torque converter housing assembly is approximately 120 kg (265 lb). Install torque converter housing assembly (2) on the torque converter.

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Illustration 46	g00503225

60. Install 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: 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".