980G Wheel Loader Power Train Transmission Planetary - Assemble - Standard Caterpillar

Assembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	1P-2420	Transmission Repair Stand	1
B	1p-0510	Driver Group	1
C	1P-7407	Eyebolt	2
D	FT-0833	Clamp	3
E	1P-1863	Retaining Ring Pliers	1
F	5P-5197	External Pliers	1
G	1P-0520	Driver Group	1
H	2P-2345	Spanner Wrench	1
J	2P-8312	External Pliers	1
K	FT-0947	Spring Compressor	2
L	2D-1201	Eyebolt	2
M	1P-7407	Eyebolt	3
N	1P-1861	Internal Pliers	1
O	1U-8758	Internal Pliers	1
P	4C-5628	Crossarm	1
	4C-5625	Puller Jaw	2
	4C-5626	Forcing Screw	1
	4C-5627	Tip	1
Q	FT-0834	Test Nozzle	1

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 in order 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 1	g00397059
Correct method for expanding the rings

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

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

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Illustration 4	g00511293

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Illustration 5	g00509504

1. Use Tooling (G) and a press to install bearing (155) in No. 1 clutch housing. Install bearing (155) with notch (156) in the UPWARD position.

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Illustration 6	g00509503

2. Use Tooling (N) to install retaining ring (154) in the groove of No. 1 clutch housing (90). The retaining ring holds bearing (155) in position.

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Illustration 7	g00509502

3. Install seal rings (152) and (153) on clutch piston (151) so that the oil grooves are facing toward the inside of the clutch housing.

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Illustration 8	g00511305

4. Apply clean transmission oil on seal rings (152) and (153). Install clutch piston (151) in No. 1 clutch housing (90) .

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Illustration 9	g00509500

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Illustration 10	g00511318

5. Install bearing (148) in planetary gear (149) .

6. Install thrust disc (150), planetary gear (149), thrust disc (147) and planetary shaft (146) in carrier assembly (135) .

7. Use a hammer and a punch to install spring pin (145) that holds planetary shaft (146) in carrier assembly (135). Make sure that the spring pin is flush with the counterbore in the carrier.

8. Repeat Steps 5 through 7 for the installation of the other three planetary gears.

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Illustration 11	g00509498

9. Install lock ring (144) in the groove of carrier assembly (135) .

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Illustration 12	g00509497

10. Use small steel rods (142) to compress the lock ring. Install carrier assembly (135) in ring gear (143) until the lock ring fits into the groove of the ring gear.

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Illustration 13	g00511401

11. Install roll pin (157) in input shaft assembly (109) .

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Illustration 14	g00511430

12. Install metal seal ring (139) in ring carrier (138) .

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Illustration 15	g00511434

13. Install ring carrier (138) on input shaft assembly (109) with the groove of ring carrier (138) around roll pin (157) .

14. Install O-ring seal (140). Apply clean oil to O-ring seal (140) .

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Illustration 16	g00511451

15. Install bearing (141) on input shaft assembly (109) .

16. Use Tooling (J) to install retaining ring (137) on input shaft assembly (109) .

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Illustration 17	g00511467

17. Mark the location of dowel (158) on carrier assembly (135), as shown.

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Illustration 18	g00511468

18. Place carrier assembly (135) on Tooling (A) .

19. Use a soft hammer to drive input shaft assembly (109) into carrier assembly (135) .

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Illustration 19	g00511477

20. Install retaining ring (136) on input shaft assembly (109) .

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Illustration 20	g00509491

21. Install metal seal rings (133) and (134) on carrier assembly (135) .

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Illustration 21	g00511480

22. Mark the location of notch (156) on bearing (155), as shown.

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Illustration 22	g00511485

23. Install Tooling (M) on No. 1 clutch housing (90). Attach a hoist and suitable lifting chains to Tooling (M) .

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Illustration 23	g00511488

24. Use the hoist to carefully lower No. 1 clutch housing (90) on carrier assembly (135). Make sure that the dowel is in alignment with the notch by the marks that were made in Steps 17 and 22. The weight of No. 1 clutch housing (135) is 66 kg (145 lb).

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Illustration 24	g00509489

25. Use Tooling (E) to install retaining ring (132) on input shaft assembly (109) .

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Illustration 25	g00511595

26. Place No. 1 clutch housing (90) with carrier assembly (135) and input shaft assembly (109) on Tooling (A), as shown.

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Illustration 26	g00509487

27. Install O-ring seal (131) on sun gear (130). Apply clean oil to O-ring seal (131) .

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Illustration 27	g00509486

28. Install sun gear (130) on input shaft assembly (109) .

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Illustration 28	g00511632

29. Install two of five dowels (95) in No. 1 clutch housing (90) .

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Illustration 29	g00511638

30. Install five friction discs (128) and four clutch plates (129) in No. 1 clutch housing (90) in alternating order. Start with a friction disc.

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Illustration 30	g00511641

31. Install dowel pins (127) in plate assembly (92). Dowel pins (127) must protrude from the plate assembly by 10.0 ± 0.5 mm (.39 ± 0.02 inch).

32. Use dowels (95) as guides to install plate assembly (92) on No. 1 clutch housing (90) .

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Illustration 31	g00511654

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Illustration 32	g00511656

33. Use Tooling (G) and a press to install bearing (125) in carrier assembly (101) .

34. Install retaining ring (124) in the groove of carrier assembly (101). The retaining ring holds bearing (125) in position.

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Illustration 33	g00509460

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Illustration 34	g00509459

35. Install bearings (117) and (121) in planetary gears (118) and (122) .

36. Install thrust disc (116), planetary gear (118) and thrust disc (119) in the lower section of carrier assembly (101). Install thrust disc (120), planetary gear (122) and thrust disc (123) in the upper section of carrier assembly (101) .

37. Install planetary shaft (115) in carrier assembly (101) .

38. Use a hammer and a punch to install spring pin (114) that holds planetary shaft (115) in carrier assembly (101). Make sure that the spring pin is flush with the counterbore in the carrier.

39. Repeat Steps 35 through 38 for the installation of the other three planetary gears.

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Illustration 35	g00509458

40. Install lock ring (113) in the groove of carrier assembly (101) .

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Illustration 36	g00509457

41. Use small steel rods (111) to compress the lock ring. Install carrier assembly (101) in ring gear (112) until the lock ring fits in the groove of the ring gear.

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Illustration 37	g00511732

42. Install seal ring (126) on carrier assembly (101) .

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Illustration 38	g00511738

43. Install carrier assembly (101) and ring gear (112) as a unit in No. 1 clutch housing (90) .

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Illustration 39	g00511753

44. Install sun gear (110) in carrier assembly (101) .

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Illustration 40	g00511757

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Illustration 41	g00509453

45. Use a pointed pry bar to lift input shaft assembly (109). Use Tooling (E) to install retaining ring (108) in the groove of input shaft assembly (109) .

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Illustration 42	g00509448

46. Use the proper equipment to handle bearing sleeve (103). Lower the temperature of bearing sleeve (103). Use Tooling (B) (not shown) to install bearing sleeve (103) in output shaft assembly (19) to a depth of 25.50 ± 0.25 mm (1.004 ± .010 inch). After assembly, the inside diameter of bearing sleeve (103) must be 35.63 ± 0.04 mm (1.403 ± .002 inch).

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Illustration 43	g00511798

47. Use the proper equipment to handle bearing sleeve (104) and bearing (107). Lower the temperature of bearing sleeve (104). Use Tooling (B) (not shown) to install bearing sleeve (104) in output shaft assembly (19) to a depth of 13.00 ± 0.25 mm (.512 ± .010 inch). After assembly, the inside diameter of bearing sleeve (104) must be 56.65 ± 0.06 mm (2.230 ± 0.002 inch).

48. Heat bearing (107) to a maximum temperature of 135 °C (275 °F). Install bearing (107) on output shaft assembly (19). The shoulder of bearing (107) must face the end of the output shaft, as shown.

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Illustration 44	g00509451

49. Install sun gear (106) on output shaft assembly (19) .

50. Use Tooling (E) to install retaining ring (105) in the groove of output shaft assembly (19) .

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Illustration 45	g00509447

51. Install O-ring seal (102) on output shaft assembly (19) .

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Illustration 46	g00511847

52. Install output shaft assembly (19) over the input shaft assembly and in carrier assembly (101) .

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Illustration 47	g00512511

53. Install retaining ring (100) in the groove of carrier assembly (101). The retaining ring holds output shaft assembly (19) in position.

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Illustration 48	g00512514

54. Install ring gear (99) on plate assembly (92) .

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Illustration 49	g00512518

55. Install five friction discs (97) and four clutch plates (98) on plate assembly (92) in alternating order. Start with a friction disc.

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Illustration 50	g00509441

56. Install remaining three dowels (95) and ten springs (96) in plate assembly (92) .

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Illustration 51	g00509440

57. Install seal rings (93) and (94) on clutch piston (91) so that the oil grooves are facing toward the inside of the clutch housing.

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Illustration 52	g00512586

58. Apply clean transmission oil on seal rings (93) and (94). Install clutch piston (91) in No. 2 clutch housing (64) .

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Illustration 53	g00512789

59. Use Tooling (D) to hold clutch piston (91) in No. 2 clutch housing (64) .

60. Fasten Tooling (L) to No. 2 clutch housing (64). Attach a hoist and suitable lifting chains to Tooling (L) .

61. Carefully install No. 2 clutch housing (64) on plate assembly (92). Make sure that springs (96) fit correctly in clutch pistons (91) and (151). The weight of No. 2 clutch housing (64) is 27 kg (60 lb).

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Illustration 54	g00509437

62. Install two bolts (89) in No. 2 clutch assembly (64) and No. 1 clutch assembly (90) .

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Illustration 55	g00512835

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Illustration 56	g00512836

63. Use Tooling (G) and a press to install bearing (88) in carrier assembly (76) .

64. Install retaining ring (87) in the groove of carrier assembly (76). The retaining ring holds bearing (88) in position.

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Illustration 57	g00509434

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Illustration 58	g00509433

65. Install bearing (84) in planetary gear (85) .

66. Install thrust disc (83), planetary gear (85) and thrust disc (86) in carrier assembly (76) .

67. Install planetary shaft (82) in carrier assembly (76) .

68. Use a hammer and a punch to install spring pin (81) that holds planetary shaft (82) in carrier assembly (76). Make sure that the spring pin is flush with the counterbore in the carrier.

69. Repeat Steps 65 through 68 for the installation of the other two planetary gears.

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Illustration 59	g00509432

70. Install lock ring (80) in the groove of carrier assembly (76) .

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Illustration 60	g00509431

71. Use small steel rods (79) to compress the lock ring. Install carrier assembly (76) in ring gear (77) until the lock ring fits in the groove of the ring gear.

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Illustration 61	g00512913

72. Install carrier assembly (76) and ring gear (77) as a unit in No. 2 clutch housing (64) .

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Illustration 62	g00512922

73. Install sun gear (78) in carrier assembly (76) .

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Illustration 63	g00509429

74. Install clutch hub (75) on carrier assembly (76) .

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Illustration 64	g00509427

75. Use Tooling (E) to install retaining ring (74) in the groove of output shaft assembly (19) .

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Illustration 65	g00512973

76. Install two of five dowels (61) in No. 2 clutch housing (64) .

77. Install three friction discs (72) and two clutch plates (73) in No. 2 clutch housing (64) in alternating order. Start with a friction disc.

78. Install ten springs (71) in No. 2 clutch housing (64) .

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Illustration 66	g00509423

79. Install two dowels (70) in No. 3 and No. 4 clutch housing (37). Dowels (70) must protrude from the clutch housing by 11.0 ± 0.5 mm (.43 ± 0.02 inch).

80. Install ten bolt dampers (69) in both sides of No. 3 and No. 4 clutch housing (37) .

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Illustration 67	g00509421

81. Install seal rings (67) and (68) on clutch piston (63) so that the oil grooves are facing toward the inside of the clutch housing.

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Illustration 68	g00513078

82. Apply clean transmission oil on seal rings (67) and (68). Install clutch piston (63) in No. 3 and No. 4 clutch housing (37) .

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Illustration 69	g00509419

83. Install seal rings (65) and (66) on clutch piston (62) so that the oil grooves are facing toward the inside of the clutch housing.

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Illustration 70	g00513090

84. Apply clean transmission oil on seal rings (65) and (66). Install clutch piston (62) in No. 3 and No. 4 clutch housing (37) .

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Illustration 71	g00509417

85. Use Tooling (K) to hold clutch pistons (62) and (63) in No. 3 and No. 4 clutch housing (37) .

86. Install Tooling (L) in No. 3 and No. 4 clutch housing (37). Attach a hoist and suitable lifting chains to Tooling (L) .

87. Use the hoist to carefully install No. 3 and No. 4 clutch housing (37) on No. 2 clutch housing (64). Make sure that springs (71) fit correctly in clutch piston (63). The weight of No. 3 and No. 4 clutch housing (37) is 52 kg (115 lb).

88. Install the remaining three dowels (61) in No. 3 and No. 4 clutch housing (37) .

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Illustration 72	g00509416

89. Install two friction discs (59) and one clutch plate (60) in No. 3 and No. 4 clutch housing (37) in alternating order. Start with a friction disc.

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Illustration 73	g00509415

90. Install ring gear (45) in No. 3 and No. 4 clutch housing (37) .

91. Install reaction plate (58) in ring gear (45) .

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Illustration 74	g00509413

92. Install four friction discs (56) and three clutch plates (57) in ring gear (45) in alternating order. Start with a friction disc.

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Illustration 75	g00513102

93. Use the proper equipment to handle ring carrier (54). Heat ring carrier (54) to a maximum temperature of 166 °C (330 °F). Install ring carrier (54) on housing assembly (33) .

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Illustration 76	g00513155

94. Use a hammer and a punch to install dowel (55) which is used to hold ring carrier (54) .

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Illustration 77	g00509411

95. Install seal rings (51) and (52) on clutch piston (50) so that the oil grooves are facing toward the inside of the housing assembly.

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Illustration 78	g00513156

96. Apply clean transmission oil on seal rings (51) and (52). Install clutch piston (50) in housing assembly (33) .

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Illustration 79	g00509409

97. Stack three disc springs (47) and install the disc springs in housing assembly (33). Make sure that the outside edges of the disc springs contact each other first.

98. Install retainer plate (49) on disc springs (47) .

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Illustration 80	g00509407

99. Place housing assembly (33) in a suitable press, as shown. Use Tooling (H) to compress three disc springs (47) in housing assembly (33) .

100. Use Tooling (J) to install retaining ring (48) in housing assembly (33) .

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Illustration 81	g00513169

101. Apply clean oil to O-ring seal (46). Install O-ring seal (46) in the groove of housing assembly (33) .

102. Install two ring seals (53) in the grooves of ring carrier (54) .

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Illustration 82	g00513175

103. Install housing assembly (33) in ring gear (45) .

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Illustration 83	g00513560

104. Install retaining ring (44) in the groove of ring gear (45). The retaining ring holds housing assembly (33) in position.

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Illustration 84	g00509403

105. Install ten springs (43) on clutch piston (62) .

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Illustration 85	g00513723

106. Use Tooling (G) to install bearing (39) in manifold assembly (7). Install bearing (39) with notch (42) against the bearing seat.

107. Use Tooling (O) to install retaining ring (38) in the groove of manifold assembly (7) .

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Illustration 86	g00509401

108. Install O-ring seal (41) on manifold assembly (7) .

109. Install dowel (40) in manifold assembly (7). Dowel (40) must protrude from the manifold assembly by 10.2 ± 0.5 mm (.40 ± .02 inch).

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Illustration 87	g00513745

110. Fasten Tooling (C) to manifold assembly (7). Attach a hoist and suitable lifting chains to Tooling (C) .

111. Use two of ten bolts (36) to install manifold assembly (7) on No. 3 and No. 4 clutch housing (37). Make sure that springs (43) fit correctly in manifold assembly (7). The weight of manifold assembly (7) is 88 kg (194 lb).

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Illustration 88	g00509396

112. Install the remaining eight bolts (36) and the washers to manifold assembly (7). Tighten the bolts to a torque of 115 ± 7 N·m (85 ± 5 lb ft).

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Illustration 89	g00513812

113. Place retaining ring (35) around housing assembly (33), as shown. At this time, DO NOT install retaining ring (33) in the groove of the housing assembly.

114. Use Tooling (F) to install retaining ring (32) on housing assembly (33) .

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Illustration 90	g00513852

115. Attach Tooling (P) on retaining ring (32). Use Tooling (P) to lift housing assembly (33) until the groove for retaining ring (35) becomes visible.

116. Use Tooling (F) to install retaining ring (35) in the groove of housing assembly (33) .

117. Remove Tooling (P) and retaining ring (32) .

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Illustration 91	g00509394

118. Install sun gear (34) on housing assembly (33) .

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Illustration 92	g00509390

119. Use Tooling (F) to install retaining ring (32) in the groove of housing assembly (33) .

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Illustration 93	g00509389

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Illustration 94	g00509388

120. Install bearings (28) and (30) in planetary gear (29) .

121. Install thrust disc (27), planetary gear (29) and thrust disc (30) in carrier assembly (20) .

122. Install planetary shaft (26) in carrier assembly (20) .

123. Use a hammer and a punch to install spring pin (25) that holds planetary shaft (26) in carrier assembly (20). Make sure that the spring pin is flush with the counterbore in the carrier.

124. Repeat Steps 120 through 123 for the installation of the other three planetary gears.

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Illustration 95	g00509365

125. Install gasket (24) with the rubber face UPWARD on carrier assembly (20) .

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Illustration 96	g00509364

126. Place slinger (23) on gasket (24) .

127. Place four locks (21) on slinger (23) .

128. Install eight bolts (22) in carrier assembly (20). Bend locks (21) upward on each bolt (22) .

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Illustration 97	g00509362

129. Install carrier assembly (20) on manifold assembly (7) .

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Illustration 98	g00509361

130. Use Tooling (E) to install retaining ring (18) in the groove of output shaft assembly (19) .

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Illustration 99	g00509359

131. Install ring gear (17) on manifold assembly (7) .

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Illustration 100	g00513883

132. Install two of six dowels (13) in manifold assembly (7) .

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Illustration 101	g00509358

133. Install three friction discs (15) and two clutch plates (16) on manifold assembly (7) in alternating order. Start with a friction disc.

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Illustration 102	g00509356

134. Install the remaining four dowels (13) and twelve springs (14) in manifold assembly (7) .

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Illustration 103	g00509355

135. Install seal rings (11) and (12) on clutch piston (10) so that the oil grooves are facing toward the inside of the clutch housing.

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Illustration 104	g00513910

136. Apply clean transmission oil on seal rings (11) and (12). Install clutch piston (10) in No. 6 clutch housing (9) .

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Illustration 105	g00513918

137. Use Tooling (D) to hold clutch piston (10) in No. 6 clutch housing (9) .

138. Fasten Tooling (C) in No. 6 clutch housing (9). Attach a hoist and suitable lifting chains to Tooling (C) .

139. Use the hoist to carefully install No. 6 clutch housing (9) on manifold assembly (7). Make sure that springs (14) fit correctly in clutch piston (10). The weight of No. 6 clutch housing (9) is 29 kg (64 lb).

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Illustration 106	g00509351

140. Install eighteen bolts (8) and the washers in No. 6 clutch housing (9). Tighten the bolts to a torque of 115 ± 7 N·m (85 ± 5 lb ft).

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Illustration 107	g00509350

141. Install two O-ring seals (5) and O-ring seal (6) to manifold assembly (7) .

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Illustration 108	g00766145
(AA) No. 4 clutch (Third speed) (BB) No. 5 clutch (Second speed) (CC) No. 6 clutch (First speed) (DD) No. 1 clutch (Reverse) (EE) No. 3 clutch (Fourth speed) (FF) No. 2 clutch (Forward)

142. Use Tooling (Q) in order to check the movement of the clutch pistons. Be sure that the clutch pistons move freely by the following steps:

     1. Put air that is free of water under a pressure of 690 to 1030 kPa (100 to 150 psi). Apply the pressurized air to each of the six oil passages.

     2. If the clutch pistons do not move, put a small amount of clean SAE 30 oil into each passage. Check for movement again. If the clutch pistons do not move, then disassemble the transmission. Check the pistons and the seal rings.

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Illustration 109	g00509347

143. Fasten Tooling (B) to planetary group (1). Attach a hoist and suitable lifting chains to Tooling (B) .

144. Use the hoist to carefully install planetary group (1) in transmission case (2). The weight of the planetary group is 425 kg (935 lb).

145. Install two bolts (3) that hold the transmission to the planetary group.

End By:

1. Install the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Install" for the machine that is being serviced.
2. Connect the transmission to the torque converter. Refer to Disassembly and Assembly, "Transmission to Torque Converter - Connect" for the machine that is being serviced.