12M Series 3, 140, 140M Series 3, 150, 160M Series 3 and and 160 Motor Graders Power Train Rear Axle, Differential and Final Drive - Assemble Caterpillar

Assembly Procedure

Note: Lubricate O-ring seals and lip-type seals with the lubricant that is being sealed.

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Illustration 1	g01355211

1. Install seals (94) onto piston (90).
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   Illustration 2	g01355208

2. Install thrust race (93), thrust bearing (92), and thrust race (91) onto piston (90).
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   Illustration 3	g01355203

3. Install piston (90). Lower the temperature of bearing assembly (89). Install bearing assembly (89).
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   Illustration 4	g01353970

4. Use two people to install housing (86) onto bevel gear (87). The weight of housing (86) is approximately 41 kg (90 lb). Install bolts (88). Tighten bolts (88) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).

5. Use a suitable lifting device to turn over bevel gear (87) and housing (86). The combined weight of bevel gear (87) and housing (86) is approximately 59 kg (130 lb).
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   Illustration 5	g01353965

6. Install thrust washer (85). Install differential gear (84).

   Note: Install thrust washer (85) with the groove side against gear (84).

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   Illustration 6	g01353954

7. Install bearing sleeve (82), pinion gear (81), and thrust washer (80) onto spider (83). Repeat this step for the remaining pinion gears (81).
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   Illustration 7	g01353945

8. Install spider assembly (79).
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   Illustration 8	g01353944

9. Install differential gear (78).
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   Illustration 9	g01353940

10. Install housing (77).

    Note: Ensure that the notches on the housings are aligned.

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    Illustration 10	g01353766

11. Install plates (74) and discs (75). Install thrust washer (73). Install springs (76).

    Note: Lubricate the discs with the lubricant that is being sealed.

    Note: Install thrust washer (73) with the groove side against the gear.

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    Illustration 11	g01353760
    Typical Example

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    Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

12. Install case (72). Install bolts (71). Tighten bolts (71) to a torque of 300 ± 40 N·m (220 ± 30 lb ft).
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    Illustration 12	g01353751

13. Install thrust ring (70). Install O-ring seals (69). Raise the temperature of bearing race (68). Install bearing race (68). Install retaining ring (67).
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    Illustration 13	g01354921

14. Raise the temperature of bearing cone (66). Install bearing cone (66) and spacer (65).

    Note: Bearing cone (66) is replaced by a bearing assembly. The bearing assembly includes a retaining clip, which holds the assembly in place. This retaining clip is for shipping and is to be discarded. The bearing assembly can either be installed as an assembly or can be disassembled and installed in individual pieces.

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    Illustration 14	g01354945

15. Lower the temperature of bearing cups (64). Install bearing cups (64).
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    Illustration 15	g01354953

16. Install bearing assembly (62). Raise the temperature of bearing cone (63). Install bearing cone (63). Install shroud (61). Apply Tooling (K) to the threads of bolts (60) and install bolts (60). Tighten bolts (60) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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    Illustration 16	g01352898

17. Attach Tooling (A) and a suitable lifting device to install bearing assembly (58) and differential (59). The weight of bearing assembly (58) and differential (59) is approximately 102 kg (225 lb).
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    Illustration 17	g01352893

18. Install shims (57), the thickness of which is equal to 2.29 mm (0.090 inch).
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    Illustration 18	g01420124

19. Attach Tooling (E) and a suitable lifting device to install intermediate housing (37). The weight of intermediate housing (37) is approximately 32 kg (71 lb).
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    Illustration 19	g01420082

20. Install bolts (56). Tighten bolts (56) to a torque of 300 ± 40 N·m (221 ± 30 lb ft). Install bolts (55). Tighten bolts (55) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
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    Illustration 20	g01419995

21. Use Tooling (G) to Install nut assembly (54). Tighten nut assembly (54) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).
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    Illustration 21	g01420086

22. Install setscrews (53). Tighten setscrews (53) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).
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    Illustration 22	g01353570

23. Lower the temperature of bearing cup (52). Install bearing cup (52). Lower the temperature of bearing cup (50). Install bearing cup (50). Raise the temperature of bearing cone (49). Install bearing cone (49) onto pinion gear (48). Install pinion (48). Raise the temperature of bearing cone (51). Install bearing cone (51).

    Note: Lubricate the splines of the pinion shaft prior to assembly.

    Note: Lubricate bearing cone (49) prior to assembly.

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    Illustration 23	g01353512

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    Illustration 24	g01353002

24. Install guard (45). Install yoke (44). Install shims (46). Install retainer (43). Install bolt (42). Tighten bolt (42) to a torque of 300 N·m (221 lb ft).

    Note: Lubricate the seal and the shaft prior to installation.

25. Ensure that the bearings are seated correctly.

26. Measure the rolling torque. Add or remove shims to obtain a rolling torque measurement of .7 to 1.7 N·m (6 to 15 lb in).

    Note: Loosen the bearing after the rolling torque is measured and shims are added or removed.

27. Remove bolt (42). Remove retainer (43). Remove shims (46). Remove yoke (44). Remove guard (45).

28. Install lip seal (47). Install guard (45). Install yoke (44). Install shims (46). Install retainer (43). Install a new bolt (42). Tighten new bolt (42) to a torque of 300 ± 40 N·m (221 ± 30 lb ft).
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    Illustration 25	g01353021

29. Install shims (40), the thickness of which is equal to 1.78 mm (0.070 inch). Do not install O-ring seal (41) now.
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    Illustration 26	g01355005

30. Use a suitable lifting device to install pinion (38). The weight of pinion (38) is approximately 56 kg (123 lb). Install bolts (39). Tighten bolts (39) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

    Note: Lubricate the O-ring seal, the shaft, and the bore with the lubricant that is being sealed prior to assembly.

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    Illustration 27	g01567895

31. Use Tooling (N) to measure the backlash between the pinion gear and the bevel gear. Prevent the bevel gear from moving while you are checking the backlash. Measure the backlash at three locations that are separated by 120 degrees. The backlash must be 0.40 + 0.00 - 0.14 mm (0.016 + 0.00 - 0.006 inch)

32. If the backlash measurement does not meet the specification, repeat Steps 18 through 22. Add shims (57) or remove shims (57) to adjust the backlash.

33. After the backlash adjustment has been made, the tooth contact between the pinion shaft and bevel gear must be checked. Use the following procedure:

    1. Put a small amount of Prussian blue, red lead, or paint on three or four adjacent teeth of the bevel gear.

    2. Rotate the pinion shaft for five to eight revolutions in one direction. Then rotate the pinion shaft for five to eight revolutions in the opposite direction.
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       Illustration 28	g01419994

    3. Attach a suitable lifting device onto pinion (38). Use Tooling (H) to separate pinion (38) from the center housing. Remove bolts (39) to remove pinion (38). Observe the contact pattern on the bevel gear. The weight of pinion (38) is approximately 56 kg (123 lb).
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    Illustration 29	g00315875

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    Illustration 30	g02066533

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    Illustration 31	g02066554

34. The middle of the contact pattern must be within the acceptable range.

35. If the contact pattern does not fall into the acceptable range, either add shims or remove shims. Recheck the contact pattern of the bevel gear. Repeat this step until the desired contact pattern is achieved.
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    Illustration 32	g01567774

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    Illustration 33	g01420124

36. Once the backlash and the contact pattern of the bevel gear are correct, Remove bolts (56) and bolts (55). Use Tooling (E) to remove intermediate housing (37). The weight of intermediate housing (37) is approximately 32 kg (71 lb).

37. Apply Tooling (L) onto the mating surface of the center housing. Install intermediate housing (37). Install new bolts (56). Tighten new bolts (56) to a torque of 300 ± 40 N·m (221 ± 30 lb ft). Install new bolts (55). Tighten new bolts (55) to a torque of 105 ± 20 N·m (77 ± 15 lb ft).
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    Illustration 34	g01353021

38. Install O-ring seal (41). Retain shims (40).

39. Once the backlash and the contact pattern of the bevel gear are correct, install new bolts (39), (55), and (56) for final assembly.
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    Illustration 35	g01355005

40. Use a suitable lifting device to install pinion (38). The weight of pinion (38) is approximately 56 kg (123 lb). Install new bolts (39). Tighten bolts (39) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).

    Note: Lubricate the O-ring seal, the shaft, and the bore with the lubricant that is being sealed prior to assembly.

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    Illustration 36	g01352445

41. Position the differential housing horizontally onto suitable blocking. Apply Tooling (L) onto the mating surface of the differential housing. Use Tooling (B) and a suitable lifting device to install ring gear (35). The weight of ring gear (35) is approximately 25 kg (55 lb).
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    Illustration 37	g01352402

42. Install gear (33) onto axle shaft (34). Install retaining ring (32).
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    Illustration 38	g01352384

43. Install axle shaft assembly (31).
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    Illustration 39	g01352406

44. Install bearings (30) into gear (28). Install gear (28). Install thrust washers (29). Install pin (27). Install retainer (26) and bolts (25). Repeat this step for the remaining planetary gears.
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    Illustration 40	g01352339

45. Install axle shaft (22) onto carrier assembly (21). Install retaining ring (24).
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    Illustration 41	g01355691

46. Raise the temperature of bearing cone (23). Install bearing cone (23).
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    Illustration 42	g01419983

47. Use Tooling (E) to install carrier assembly (21) and drive shaft (22). The weight of carrier assembly (21) and drive shaft (22) is approximately 136 kg (300 lb).
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    Illustration 43	g01352320

48. Lower the temperature of bearing cup (20). Install bearing cup (20). Install lip seal (19).
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    Illustration 44	g01527277

49. Apply Tooling (S) onto thrust washer (18). Apply Tooling (S) onto surface (X) and surface (Y). Install thrust washer (18). Lower the temperature of bearing cup (17). Install bearing cup (17).
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    Illustration 45	g01352299

50. Install lip seal (16) into housing (13).
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    Illustration 46	g01355702

51. Turn over housing (13). Install wear sleeves (15). The diagonal cuts that are in wear sleeves (15) are separated by 90°. Apply Tooling (S) onto thrust washer (14). Install thrust washer (14).
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    Illustration 47	g02033793

52. Use Tooling (A) and a suitable lifting device to install housing (13). The weight of housing (13) is approximately 54 kg (120 lb). Install shims (12). Use a suitable soft hammer to drive the wear sleeves into housing (13) until the sleeves are flush with the top of the bore surface. Do not install the shims now.
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    Illustration 48	g02033646

53. Drill three equally spaced 8 mm (5/16 inch) holes in retainer (11). The holes must be centered on the existing bolt hole pattern and perpendicular to each surface.

54. Measure the thickness of retainer (11) at the three hole locations. Average the three measurements and record the result as Dimension (A).
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    Illustration 49	g02033655

55. Install retainer (11). Install three of bolts (10). Tighten bolts (10) to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Completely loosen bolts (10). Finger tighten bolts (10). Use Tooling (T) to measure the gap between the top surface of retainer (11) and the final drive housing at the three 8 mm (5/16 inch) hole locations. Record the measurement from each of the three locations as the nominal gap or Dimension (B).

56. Calculate the shim pack thickness for the three measurement locations by subtracting Dimension (A) from the Dimension (B) giving you Dimension (C). Remove bolts (10) and retainer (11).
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    Illustration 50	g02033934

57. Install shims (12), the thickness of which is equal to Dimension (C) plus + 0.075 - 0.025 mm (+ 0.0030 - 0.0010 inch). Install retainer (11). Install bolts (10). Tighten bolts (10) to a torque of 270 ± 40 N·m (199 ± 30 lb ft).
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    Illustration 51	g01414071

58. Apply Tooling (L) to the mating surface of final drive housing (8). Use Tooling (A), Tooling (C), and two suitable lifting devices to install final drive housing (8). The weight of final drive housing (8) is approximately 191 kg (420 lb). Install bolts (9A). Tighten bolts (9A) to a torque of 105 ± 20 N·m (77 ± 15 lb ft). Install nuts (9). Tighten nuts (9) to a torque of 130 ± 30 N·m (96 ± 22 lb ft). Turn nuts (9) an additional 50° ± 10°.
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    Illustration 52	g01414357

59. Install bearing cone (7).
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    Illustration 53	g06373424

60. If necessary, rework retainer (4) as shown in figure 53. Drill three 6.40 mm (0.25 inch) evenly spaced holes (Y) on a circle with a diameter of 55.00 mm (2.16 inch) on retainer (4).
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    Illustration 54	g01418566

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    Illustration 55	g01414028
    typical example

61. Install sprocket (2) and sprocket (6) onto rear axle (1).

    Note: Assemble sprocket (2) and sprocket (6) so that the teeth on the sprockets are aligned with each other.

62. Position retainer (4) on the sprocket with no shims installed. Install bolts (3) finger tight against retainer (4). Tighten bolts (3) to the seating torque value of 80 N·m (59 lb ft). Repeat until bolts (3) no longer turn. Rotate sprocket (2) three full revolutions. Bolt (3) will have to be tightened several times. After each tightening sequence, rotate sprocket (2) three full revolutions until the bolt torque has equalized at 80 N·m (59 lb ft).

63. Loosen bolts (3), and finger tighten against retainer (4). With bolts (3) finger tight only, rotate sprocket (2) three full revolutions.

64. Tighten bolts (3) to the preload adjusting torque of 20 N·m (177lb in). Repeat until bolts (3) no longer move. Rotate sprocket (2) three full revolutions. Bolt (3) will have to be tightened several times. After each tightening sequence, rotate sprocket (2) three full revolutions until the bolt torque has equalized at 20 N·m (177lb in).

65. Use Tooling (M) to measure the distance from the face of the spindle shaft to surface (X) in three places and record the average distance. Remove bolts (3) and retainer (4). Measure the thickness of retainer (4). Subtract the thickness of retainer (4) from the average distance measured previously, to determine the gap between the end of the spindle shaft and retainer (4).

66. Install shims (5), the thickness of which is equal to the measured gap plus 0.073 mm (0.0029 inch). The determined shim pack thickness can have a tolerance of +0.00/-.025 mm (+0.00/-.001 inch).
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    Illustration 56	g01418569

67. Install retainer (4). Apply Tooling (R) to bolts (3) and install. Tighten bolts (3) to a torque of 270 ± 40 N·m (200 ± 30 lb ft).

68. Repeat Step 41 through Step 67 for the opposite side.

End By:

1. Install the rear axle.