938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power Train Transmission - Assemble Caterpillar


Transmission - Assemble
`
1.1. Assembly Procedure

Assembly Procedure

Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     138-7573     Link Bracket     1    
C     1P-2420     Transmission Repair Stand     1    
D     2P-8312     Retaining Ring Pliers     1    
E     8S-2328     Dial Indicator Gp     1    
F     9U-7480     Compressing Tube     1    
G     1P-1863     Retaining Ring Pliers     1    
H     9U-7479     Compressing Tube     1    
J     1U-6341     Threaded Rod     1    
K     5P-7970     Nut     1    
M     1P-0520     Driver Gp     1    



    Illustration 1g00960522

  1. Install bearing (158) , bearing cup (159) , and seal (160) in cover (155) .



    Illustration 2g00960379

  1. Install bearings (156) and (157) in cover (155) .

  1. Install the torque converter to cover (155) .



    Illustration 3g00984256

  1. Install magnetic screen (154) and suction screen (153) .



    Illustration 4g00984255

  1. Install cover (152) and install bolts (151) .



    Illustration 5g00984254

  1. Lower the temperature of cup (150) . Install cup (150) , seal (149) , and shims (148) in bearing cage (146) .



    Illustration 6g00984253

  1. Install bearing cage (146) and bolts (147) in transmission case (132) .



    Illustration 7g00984252

  1. Raise the temperature of bearing cone (145) and install bearing cone (145) and gear (144) on shaft (133) .



    Illustration 8g00984251

  1. Install shaft assembly (133) .



    Illustration 9g00986212



    Illustration 10g00986213



    Illustration 11g00984249

  1. Lower the temperature of cup (141) and install cup (141) with Tooling (M) .

  1. Use Tooling (M) in order to install seal (142) .

  1. Install shims (140) , bearing cup (141) , seal (142) , and seal (143) in bearing cage (139) .



    Illustration 12g00984247

  1. Install the bearing cage and install bolts (138) .



    Illustration 13g00986214

  1. Raise the temperature of bearing cone (131) . Install bearing cone (131) on shaft (133) .



    Illustration 14g00984240

  1. Lower the temperature of bearings (128) , (129) , and (130) . Install the bearings in transmission case (132) .



    Illustration 15g00984239

  1. Install thrust disc (127) in transmission case (132) .



    Illustration 16g00984236

  1. Install seals (124) and (126) on piston (124) .



    Illustration 17g00984232

  1. Balance seal assembly (124) , wave spring (123) , and piston (122) upon installation. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.



    Illustration 18g00979099

  1. Install piston (124) .



    Illustration 19g00979091

  1. Install wave spring (123) .



    Illustration 20g00979089

  1. Install balance piston (122) .



    Illustration 21g00979073



    Illustration 22g00979077

  1. Position the shaft assembly so snap ring (121) lines up with the opening on Tooling (H) .

  1. Install Tooling (H) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) in order to install snap ring (121) . Remove Tooling (H) .



    Illustration 23g00979070

  1. Use Tooling (G) to install snap ring (120) .



    Illustration 24g00979064

  1. End plate (117) , clutch plates (118) , and friction discs (119) upon installation.



    Illustration 25g00979063

  1. Install one friction discs (119) , clutch plates (118) , and end plate (117) .



    Illustration 26g00979060

  1. Install retaining ring (116) .



    Illustration 27g00979059

  1. Install ring retainer (115) and thrust disc (114) .



    Illustration 28g00744470



    Illustration 29g00744313

    Typical Example

    (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

  1. Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    1. Make sure that End Plate (W) is free.

    1. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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

      Personal injury can result from applying air pressure without the lock ring securely in place.

      If the lock ring is not secure, the end plate and discs can suddenly come out with great force.

      Make sure lock ring is securely in place before applying air pressure to clutch pack.

      ----------------------

    1. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    1. End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.



    Illustration 30g00979056

  1. Connect hub assembly (112) to gear (110) .

  1. Use Tooling (G) to install retaining ring (111) .

  1. Install sleeve bearing (113) .

    Note: After the bearing is installed, the diameter must be 79.113 ± .05 mm (3.1147 ± 0.0020 inch).




    Illustration 31g00979054

  1. Install gear and hub assembly (110) .



    Illustration 32g00979049

  1. Install thrust disc (109) .



    Illustration 33g00979043

  1. Install gear (108) .



    Illustration 34g00979038

  1. Use Tooling (D) to install retaining ring (107) .



    Illustration 35g00977455

  1. Install thrust disc (106) .



    Illustration 36g00977453

  1. Install seal rings (105) .



    Illustration 37g00977449

  1. Attach a suitable lifting device and rotate shaft (78) to the opposite side. The weight of shaft (78) is approximately 45 kg (100 lb).



    Illustration 38g00977446

  1. Balance seal assembly (102) , wave spring (103) , and piston (104) upon installation. Check the lips on the seals for damage or wear. Replace the seals, if necessary.



    Illustration 39g00977444

  1. Install piston (104) on the shaft.



    Illustration 40g00977441

  1. Install wave spring (103) .



    Illustration 41g00977438

  1. Install balance seal assembly (102) .



    Illustration 42g00977426

  1. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown).

  1. Use Tooling (D) to install retaining ring (101) . Release the pressure on the wave spring and remove Tooling (F) .



    Illustration 43g00977424



    Illustration 44g00977433

  1. Install one disc assembly (99) , clutch plates (100) , and end plate (98) .



    Illustration 45g00977422

  1. Install retaining ring (97) .



    Illustration 46g00977380

  1. Use Tooling (D) to install retaining ring (96) .



    Illustration 47g00744470



    Illustration 48g00744313

    Typical Example

    (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

  1. Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    1. Make sure that End Plate (W) is free.

    1. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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

      Personal injury can result from applying air pressure without the lock ring securely in place.

      If the lock ring is not secure, the end plate and discs can suddenly come out with great force.

      Make sure lock ring is securely in place before applying air pressure to clutch pack.

      ----------------------

    1. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (Z) in the shaft for the clutch that is being checked.

    1. End Plate (W) should moveupward and End Plate (W) should contact retaining ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.



    Illustration 49g00976232

  1. Install retainer (95) and thrust disc (94) .



    Illustration 50g00976230

  1. Connect hub assembly (92) to gear (90) .

  1. Install bearing (93) in hub assembly (92) .

    Note: After bearing (93) is installed the inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).

  1. Use Tooling (D) to install retaining ring (91) .



    Illustration 51g00976229

  1. Install gear (90) .



    Illustration 52g00976228

  1. Install thrust disc (89) . Use Tooling (D) to install retaining ring (88) .



    Illustration 53g00976227

  1. Position shaft assembly (87) on Tooling (C) .



    Illustration 54g00976215

  1. Use Tooling (A) and a suitable lifting device to install shaft assembly (87) . The weight of shaft assembly is approximately 82 kg (180 lb).



    Illustration 55g00976189

  1. Install sensors (85) and (86) .



    Illustration 56g00986223

  1. Lower the temperature of bearing cone (83) and gear (84) . Turn shaft (78) in order to install bearing cone (83) , and gear (84) .



    Illustration 57g00986224



    Illustration 58g00975867

  1. Lower the temperature of carrier (80) , bearing cone (81) , and gear (82) . Install the bearings on shaft (78) .

  1. Install seal ring (79) .



    Illustration 59g00975828

  1. Install input shaft group (78) .



    Illustration 60g00988354

  1. Install seal rings (76) , and (77) on piston (75) . Replace the seals if it is necessary.



    Illustration 61g00975818

  1. Install piston seal (75) .



    Illustration 62g00975812

  1. Install wave spring (74) .



    Illustration 63g00975811

  1. Install balance seal assembly (73) .



    Illustration 64g00975810

  1. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (G) to install retaining ring (72) . Remove Tooling (F) .



    Illustration 65g00975588

  1. Position the shaft assembly so the opening in retaining ring (72) will be in line with the opening in Tooling (F) .



    Illustration 66g00975587

  1. End plate (69) , clutch plates (70) , and friction discs (71) upon installation.



    Illustration 67g00975585

  1. Install one friction discs (71) , clutch plates (70) , and end plate (69) .



    Illustration 68g00975584

  1. Install retaining ring (68) . Use Tooling (D) to install retaining ring (67) .



    Illustration 69g00975579

  1. Install retainer (66) and thrust disc (65) .



    Illustration 70g00744470



    Illustration 71g00744313

    Typical Example

    (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

  1. Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    1. Make sure that End Plate (W) is free.

    1. Position the tip of Tooling (E) onEnd Plate (W) . Zero Tooling (E) .

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

      Personal injury can result from applying air pressure without the lock ring securely in place.

      If the lock ring is not secure, the end plate and discs can suddenly come out with great force.

      Make sure lock ring is securely in place before applying air pressure to clutch pack.

      ----------------------

    1. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    1. End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.



    Illustration 72g00975578

  1. Install two sleeve bearings (64) , if necessary.

    Note: Bearing (64) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).




    Illustration 73g00975576

  1. Install gear assembly (63) and thrust disc (62) .



    Illustration 74g00975570

  1. Position the shaft assembly with the opposite end upward, as shown. Install three seal rings (60) . Use Tooling (D) to install retaining ring (61) .



    Illustration 75g00988355

  1. Install seal rings (59A) , and (59B) on piston (59) . Replace the seals if it is necessary.



    Illustration 76g00975564

  1. Install piston assembly (59) .



    Illustration 77g00975562

  1. Install wave spring (58) .



    Illustration 78g00975558

  1. Install balance seal assembly (57) .



    Illustration 79g00975555

  1. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. Use Tooling (D) to install the retaining ring (56) . Remove Tooling (F) .



    Illustration 80g00975553

  1. Position the shaft so the opening in retaining ring (56) will line up with the opening in Tooling (F) .



    Illustration 81g00975467

  1. Install one friction discs (55) , clutch plates (54) , and end plate (53) .



    Illustration 82g00975463

  1. Install retaining ring (52) .



    Illustration 83g00975458

  1. Use Tooling (D) to install retaining ring (51) .



    Illustration 84g00744470



    Illustration 85g00744313

    Typical Example

    (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

  1. Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    1. Make sure that End Plate (W) is free.

    1. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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

      Personal injury can result from applying air pressure without the lock ring securely in place.

      If the lock ring is not secure, the end plate and discs can suddenly come out with great force.

      Make sure lock ring is securely in place before applying air pressure to clutch pack.

      ----------------------

    1. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    1. End Plate (W) should moveupward and end plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.



    Illustration 86g00975456

  1. Install retainer (50) and thrust disc (49) .



    Illustration 87g00975454

  1. Install sleeve bearing (48) , if necessary. Connect gear (45) to hub assembly (47) . Use Tooling (G) to install retaining ring (46) .

    Note: Bearing (48) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).




    Illustration 88g00975452

  1. Install gear and hub assembly (45) .



    Illustration 89g00975449

  1. Install thrust disc (44) . Use Tooling (D) to install retaining ring (43) .



    Illustration 90g00975447

  1. Position shaft (42) on Tooling (C) , as shown.



    Illustration 91g00974967

  1. Use Tooling (A) and a suitable lifting device in order to install shaft assembly (42) . The weight of shaft assembly is approximately 41 kg (90 lb).



    Illustration 92g00988356

  1. Install seal rings (41A) , and (41B) on piston (41) . Replace the seals, if necessary.



    Illustration 93g00974965

  1. Install piston seal (41) .



    Illustration 94g00974964

  1. Install wave spring (40) .



    Illustration 95g00974963

  1. Install balance seal assembly (39) .



    Illustration 96g00974961



    Illustration 97g00974962

  1. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to install retaining ring (38) and remove Tooling (F) .

  1. Position the shaft assembly with the opening in retaining ring (38) in line with the opening in Tooling (F) .



    Illustration 98g00974960

  1. Exploded view of end plate (35) , clutch plates (36) , and friction discs (37) upon installation.



    Illustration 99g00974959

  1. Install one friction discs (37) , clutch plates (36) , and end plate (35) .



    Illustration 100g00974958

  1. Install retaining ring (34) .



    Illustration 101g00974957

  1. Use Tooling (D) to install retaining ring (33) .



    Illustration 102g00744470



    Illustration 103g00744313

    Typical Example

    (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

  1. Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    1. Make sure that End Plate (W) is free.

    1. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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

      Personal injury can result from applying air pressure without the lock ring securely in place.

      If the lock ring is not secure, the end plate and discs can suddenly come out with great force.

      Make sure lock ring is securely in place before applying air pressure to clutch pack.

      ----------------------

    1. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    1. End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.



    Illustration 104g00974956

  1. Install retainer (32) and thrust disc (31) .



    Illustration 105g00974955

  1. Connect gear (27) to hub assembly (29) . Use Tooling (G) to install retaining ring (28) . If necessary, install sleeve bearing (30) .

    Note: Bearing (30) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).




    Illustration 106g00974954

  1. Install hub assembly (27) , thrust disc (26) , and the gear.



    Illustration 107g00974953

  1. Install spacer assembly (25) .



    Illustration 108g00974951

  1. Install gear (24) and washer (23) .



    Illustration 109g00974950

  1. Install thrust disc (22) .



    Illustration 110g00974949

  1. Reposition the shaft assembly, as shown. Install three seal rings (20) . Use Tooling (D) to install retaining ring (21) .



    Illustration 111g00974948

  1. Balance seal assembly (17) , wave spring (18) , and piston (19) upon installation. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.



    Illustration 112g00974947

  1. Install piston assembly (19) .



    Illustration 113g00961678

  1. Install wave spring (18) .



    Illustration 114g00961656

  1. Install balance seal assembly (17) .



    Illustration 115g00961647

  1. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to install retaining ring (16) . Remove Tooling (F) .



    Illustration 116g00961639

  1. Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) .



    Illustration 117g00961630

  1. End plate (13) , clutch plates (14) , and friction plates (15) .



    Illustration 118g00961507

  1. Install one friction discs (15) , clutch plates (14) , and end plate (13) .



    Illustration 119g00961492

  1. Install retaining ring (12) .



    Illustration 120g00961468

  1. Install retaining ring (11) .



    Illustration 121g00744470



    Illustration 122g00744313

    Typical Example

    (W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.

  1. Use Tooling (E) , a suitable air supply and the following procedure to measure the running clearance of the clutch pack:

    1. Place the shaft in the vertical position. End Plate (W) that will be measured should be facing upward.

    1. Make sure that End Plate (W) is free.

    1. Position the tip of Tooling (E) on End Plate (W) . Zero Tooling (E) .

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

      Personal injury can result from applying air pressure without the lock ring securely in place.

      If the lock ring is not secure, the end plate and discs can suddenly come out with great force.

      Make sure lock ring is securely in place before applying air pressure to clutch pack.

      ----------------------

    1. Apply air pressure of approximately 140 kPa (20 psi) to appropriate Passage (Z) in the shaft for the clutch that is being checked.

    1. End Plate (W) should moveupward and End Plate (W) should contact Retaining Ring (X) . The dial indicator will display the distance between End Plate (W) and Retaining Ring (X) . This is the running clearance of the clutch pack. For the proper running clearance, refer to the Testing and Adjusting, "Transmission Clutch Running Clearance - Check" for the machine that is being serviced.



    Illustration 123g00961455

  1. Install retainer (10) and thrust disc (9) .



    Illustration 124g00961444

  1. Use Tooling (G) to install retaining ring (6) .

  1. Connect hub (7) and gear (5) . If necessary, install sleeve bearing (8) .

    Note: Bearing (8) inside diameter must be 65.046 ± .039 mm (2.5609 ± 0.0015 inch).




    Illustration 125g00961435

  1. Install gear and hub assembly (5) .



    Illustration 126g00961189

  1. Use Tooling (D) to install retaining ring (3) and install thrust disc (4) .



    Illustration 127g00961151

  1. Position shaft (1) on Tooling (C) , as shown.



    Illustration 128g00984312

  1. Install Tooling (A) to shaft (1) . Attach a suitable lifting device to Tooling (A) .

    Note: Hold input shaft (2) away from shaft (1) for clearance.

  1. Use a suitable lifting to lower shaft (1) straight up out of transmission case. The weight of shaft (1) is approximately 50 kg (110 lb).

    Note: Connect the transmission and the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Connect".




    Illustration 129g00748030

  1. Use shims to obtain a thickness of 0.05 mm (0.002 inch) to 0.15 mm (0.006 inch). Use Tooling (E) to check the end play on the output shaft and the input shaft.



    Illustration 130g00988280

  1. Use Tooling (E) to check the end play. Make sure that the shafts are free. The maximum end play is 0.05 mm (0.002 inch) to 0.15 mm (0.006 inch).



    Illustration 131g00748037

  1. Use shims to obtain a thickness of 0.05 mm (0.002 inch) to 0.15 mm (0.006 inch). Use Tooling (E) to check the end play on the input shaft.



    Illustration 132g00984245

  1. Install parking brake group (137) . Install bolts (136) .



    Illustration 133g00984244

  1. Install the yoke and brake drum (135) . Install bolts (134) . Rotate the transmission case.

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