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Product:  TRUCK
Model:  789C TRUCK 2BW
Configuration: 789C Off-Highway Truck 2BW00001-UP (MACHINE) POWERED BY 3516
Engine

Disassembly and Assembly

789C Off-Highway Truck Machine Systems
Media Number -SENR1534-12 Publication Date -01/07/2013 Date Updated -01/07/2013

    i05985170

Pin (Rear Axle Housing) - Install

SMCS - 3260-012-PN

Installation Procedure
Table 1
Required Tools 

Tool  Part Number  Part Description  Qty 

9U-7489  Lift Stand  1 

A  350-7768 Electric Hydraulic Pump Gp(115V)  - 

350-7769 Electric Hydraulic Pump Gp(230V)  - 

B  214-6571  Socket  1 

7X-0871  Tee  2 

C  6V-3965 Fitting  2 

FT-1845 Pump Group  1 

485-8004  Support Stand  1 

D 
1U-9749 Transmission Jack  1 

E  350-7768  Electric Hydraulic Pump Gp(115V)  - 

350-7769 Electric Hydraulic Pump Gp(230V)  - 

6V-3160 Double Acting Cylinder  1 

4C-9493 Sleeve  1 

9U-6832 Nut  2 
 4K-0684 Hard Washer  2 

9U-6907 Bearing Puller Adapter  1 

4C-9634 Puller Stud  1 

F  6V-2012  Depth Micrometer  1 

G  -  Loctite Graphite-50 A/S  - 

1. Verify that all the components are clean and free of foreign material prior to installation.
Inspect all the O-ring seals and the components for wear. Replace the O-ring seals and the
components, if necessary.

Illustration 1 g06401011

When you are using hydraulic cylinders and puller studs,

always ensure that the rated capacity of the puller stud
meets or exceeds the rated capacity of the hydraulic
cylinder. If the puller stud does not meet or exceed the rated
capacity of the hydraulic cylinder, a sudden failure of the
puller stud could occur. The sudden failure of the puller stud
could result in personal injury or death.

2. Use Tooling (E) to install bearing (21) into rear axle housing (4).
 Illustration 2 g06401015

3. Position plates (20) onto rear axle housing (4). Install bolts (19). Tighten bolts (19) to a
torque of 270 ± 25 N·m (199 ± 18 lb ft).

Illustration 3 g06401018

4. Install washer (18) and onto pin (16). Position pin (16) into rear axle housing (4). The
weight of pin (16) is approximately 75 kg (166 lb)

Illustration 4 g06401021

Note: Lubricate the pin bore of the cap assembly with Tooling (G).

5. Install ring (17) and cap assemblies (15) onto pin (16).
 Illustration 5 g00626029
Typical Example

6. Install plate (13). Install three of bolts (12), equally spaced. Tighten bolts (12) to a torque
of 200 ± 25 N·m (148 ± 18 lb ft). Use Tooling (F) to measure the distance between the pin
and the outside surface of plate (13).

7. Remove bolts (12) and plate (13).

8. Measure the thickness of plate (13) and subtract this value from the value that was
obtained in Step 6.

Illustration 6 g06401024

9. Install a number of shims that equals the value that was obtained in Step 14 plus 0.25 mm
(0.01 inch). Install plate (13). Install bolts (12). Tighten bolts (12) to a torque of
750 ± 90 N·m (555 ± 66 lb ft)
 Illustration 7 g00517051

Illustration 8 g02200395

10. Use Tooling (A) to lower the frame assembly and raise rear axle housing (4) by
approximately 75 mm (3 inch) to connect rear axle housing (4) to the frame assembly.

Illustration 9 g02200293

11. Apply Tooling (G) to the washers and the threads of bolts (14).

12. Use Tooling (B) to install bolts (14) and connect bearing cap (15) to the frame assembly.
Tighten bolts (14) to a torque of 475 ± 50 N·m (350 ± 37 lb ft). After bolts (14) have been
tightened, turn bolts (14) by an extra 60 ± 5 degrees.
 Note: Tooling (B) must be modified to install the bolts that are closest to the frame
assembly. Remove the top 20 mm (0.8 inch) from Tooling (B).

13. Repeat Steps 12 for the remaining bearing cap.

Illustration 10 g00627913

14. Use a suitable lifting device to position drive shaft (11). Install new bolts (10). Tighten
bolts (10) to a torque of 550 ± 20 N·m (406 ± 15 lb ft).

Illustration 11 g00625955

15. Position plate (9) and install bolts (8).

Illustration 12 g00625945
16. Position hose assembly (5) and hose assembly (6). Install bolt (7).

Illustration 13 g00625948

17. Connect hose assembly (5) to rear axle housing (4).

Illustration 14 g00625943

18. Position hose assembly (2) and install bolt (3).

Illustration 15 g00625941

19. Connect hose assembly (2) to magnetic screen (1).

 20. Refill the transmission tank with hydraulic oil. Refer to Operation and Maintenance
Procedure, "Transmission Tank Oil - Change".

End By:

a. Install the hoist control valve. Refer to Disassembly and Assembly, "Control Valve (Hoist) -
Remove".

b. Remove the wheel chocks. Refer to Disassembly and Assembly, "Wheel Chock (Front and
Rear) - Remove and Install".

Copyright 1993 - 2019 Caterpillar Inc.

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