1/8/23, 10:19 SIS 2.

2023/02/07 Transmission and Torque Converter - Assemble (RENR6422-07)

SMCS - 3001 i09728946

Assembly Procedure PPI

Table 1 -
202 0007
Required Tools

Tool Part Number Part Description

3 /
14: 08/0 0FDC Qty
A 1P-2420 1
RE 8:55- 1
Transmission Repair Stand 1

C
B 180-3033
138-7574
N
© 2 R64 04:00
Repair Stand Set
Link Bracket
1
2
D 4C-6136
023 22
Lifting Bracket 1
E 4C-6399
Cat
Compressor Assembly (Clutch Spring) 1
F FT-2343
erp
Plexiglass Cover 1
H 4C-3652
illa
Compressor Assembly (Clutch Spring) 1
J 4C-6402 Expander Tool Gp
r In 1

K
4C-6137
4C-6142
Bearing Installer
Spacer
c. 1
1
1P-0531 Handle 1
L 5P-3413 Pipe Sealant 1
M 9S-3263 Thread Lock Compound 1
N 1U-8846 Gasket Sealant 1
P 4C-6143 Clutch Piston Installer 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.

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Illustration 1 g01005243

1. Install gear (149) and retaining ring (148). Raise the temperature of bearing cone (147).
Install bearing cone (147).

Illustration 2 g01005241

2. Raise the temperature of bearing cone (146). Install bearing cone (146).

Illustration 3 g01005239

3. Apply Tooling (L) to the seal bore.

4. Install lip seal (145). Lubricate the sealing lip with the lubricant that is being used.
Note: Lip seal (145) should be flush with surface.
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5. Lower the temperature of bearing cup (143). Install bearing cup (143).

6. Use bolts (142) to install shield assembly (144). Tighten bolts (142) to a torque of
55 ± 10 N·m (40 ± 10 lb ft).

Illustration 4 g01005238

7. Install the output shaft and gear (141).

Illustration 5 g01005236

8. Install lip seal (140). Lubricate the sealing lip with the lubricant that is being used.

9. Lower the temperature of bearing cup (139). Install bearing cup (139).

10. Install seal (138).

11. Install shims (137). Use the shims to get 0.06 mm (0.002 inch) to 0.13 mm (0.005 inch) end
play on the output shaft.
Note: Lubricate the bore of the housing with the lubricant that is being used.

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Illustration 6 g00655180
12. Use bolts (135) to install the cage. Tighten bolts (135) to a torque of 70 ± 10 N·m
(50 ± 10 lb ft).

Illustration 7 g00890758

13. Install parking brake assembly (133) and lever (134).

14. Use bolts (131) to install plate (132). Tighten bolts (131) to a torque of 120 ± 20 N·m
(90 ± 15 lb ft).

Illustration 8 g00890622

15. Install brake drum (130) and yoke (129) together. Install seal (128).

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Illustration 9 g00685060
16. Install the bolt and washer (127). Tighten bolt (127) to a torque of 120 ± 20 N·m
(90 ± 15 lb ft).

Illustration 10 g00655120

17. Use washer (125) and bolt (124) to install yoke (126). Tighten bolt (124) to a torque of
120 ± 20 N·m (90 ± 15 lb ft).

Illustration 11 g00655110

18. Lower the temperature of bearing cups (123). Install bearing cups (123). Use Tooling (J) to
install bearing (122).

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Illustration 12 g00890621
19. Install gear (119). Raise the temperature of bearing cone (118). Install bearing cone (118).

20. Install gear (120). Raise the temperature of bearing cone (121). Install bearing cone (121).

21. Install seal (116) on carrier (117) and install carrier (117).

Illustration 13 g00655016

22. Install the input shaft assembly (115).

Illustration 14 g00654969

23. Install seals (112), (113), and (114).

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Illustration 15 g00654966
Note: Lubricate the piston, and the bore with clean transmission oil.
24. Use Tooling (P) to install piston (111).

Illustration 16 g00654842

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.

25. Install spring (110).

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Illustration 17 g00654837
26. Install the retainer and seal assembly (109).

Illustration 18 g00654833

27. Put the clutch pack in a suitable press. Use Tooling (H) to install retaining ring (108).

Illustration 19 g00654824

28. Lower the temperature of bearing assembly (107). Install bearing assembly (107).

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Illustration 20 g00654818
29. Install ring (106).

Illustration 21 g00890619
Note: Refer to Specifications, "Power Shift Transmission" for the specifications of the clutch
discs.

30. Install plates and discs (105). Install retaining ring (103). Install washers (104) and (102).

Illustration 22 g00654724

31. Install hub assembly (101).

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Illustration 23 g00654719
32. Install gear (100) and retaining ring (99). Install washer (98).

Illustration 24 g07574140

33. Install gear (95) and washer (96). Raise the temperature of bearing (97). Install bearing (97)
and retaining ring (97A).
Note: This completes the assembly of the first gear clutch pack.

Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure
running clearance.

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Illustration 25 g00654638
34. Install seals (94) and (93).

Illustration 26 g00890838
Note: Lubricate the piston, and the bore with clean transmission oil.

35. Use Tooling (P) to install piston (90).

36. Install seals (92) on shaft (91).

Illustration 27 g00654534

37. Install spring (89) and retainer (88).

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Illustration 28 g00654525

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.

38. Put the third gear clutch pack in a suitable press. Use Tooling (H) to install retaining ring
(87).

Illustration 29 g00654519
Note: Refer to Specifications, "Power Shift Transmission" for the specifications of the clutch
discs.

39. Install plates and discs (86). Install retaining ring (85).

40. Install washer (84).

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Illustration 30 g00654517
41. Use a suitable press to install bearing (83). Install retaining ring (82).

Illustration 31 g00654512

42. Install hub assembly (81).

Illustration 32 g00654507

43. Install gear (80) and retaining ring (79).

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Illustration 33 g00654497
44. Install washer (78) and retaining ring (77).
Note: This completes the assembly of the third gear clutch pack.

Note: Refer to Specifications, SENR3504 , "Power Shift Transmission" for the procedure to
measure running clearance .

Illustration 34 g00654494

45. Use Tooling (D) to install third gear clutch pack (76). The weight of third gear clutch pack
(76) is approximately 50 kg (110 lb).

Illustration 35 g00890612

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1/8/23, 10:19 SIS 2.0

Note: Use Steps 46 through 49 for the assembly of the clutch of the second gear clutch
pack. Use Tooling (E) in step 49 instead of Tooling (H).
46. Install washers (75) and (74). Install spacer (73).

47. Install gear (72), spacer (70), and bearing cone (71).

Illustration 36 g00654403

48. Install seals (69) and (68).

Illustration 37 g00890841

Illustration 38 g00654372
Note: Lubricate the piston and the bore with clean transmission oil.
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1/8/23, 10:19 SIS 2.0

49. Use Tooling (P) to install piston (65). Install seals (66) on shaft (67).

Illustration 39 g00654364

50. Install spring (64) and retainer (63).

Illustration 40 g00654360

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.

51. Put the reverse clutch pack in a suitable press. Use Tooling (H) to install retaining ring (62).

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Illustration 41 g00890611
52. Use a suitable press to install bearing (61). Install retaining ring (60).

Illustration 42 g00890610
Note: Refer to Specifications, "Power Shift Transmission" for the specifications of the clutch
discs.

53. Install plates and discs (59). Install retaining ring (57).

54. Install washer (58).

Illustration 43 g00654347

55. Install hub assembly (56).

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Illustration 44 g00654328
56. Install gear (55) and retaining ring (54).

Illustration 45 g00654339

57. Install washer (53) and retaining ring (52).

Note: This completes the assembly of the reverse second gear clutch pack.

Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure
running clearance.

Illustration 46 g00654301

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1/8/23, 10:19 SIS 2.0

58. Use Tooling (D) to install reverse second gear clutch pack (51). The weight of reverse
second gear clutch pack (51) is approximately 32 kg (70 lb).

Illustration 47 g00654292

59. Install seals (49) and (50).

Illustration 48 g00654280
Note: Lubricate the piston, and the bore with clean transmission oil.

60. Use Tooling (P) to install piston (47).

61. Install spring (46) and retainer (45).

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1/8/23, 10:19 SIS 2.0

Illustration 49 g00654276

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.

62. Put the forward high clutch pack in a suitable press. Use Tooling (H) to install retaining ring
(44).

Illustration 50 g00654274
Note: Refer to Specifications, "Power Shift Transmission" for specifications of the clutch
discs.

63. Install plates and discs (43). Install retaining ring (42). Install washer (41).

Illustration 51 g00654263

64. Use a suitable press to install bearing (40). Install retaining ring (39).

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Illustration 52 g00654261
65. Install hub (38).

Illustration 53 g00654253

66. Raise the temperature of gear (37). Install gear (37). Install retaining ring (36).

Illustration 54 g00654078

67. Install washer (35) and retaining ring (34).

Note: This completes the assembly of the forward high gear clutch pack.

Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure
running clearance.

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Illustration 55 g00654063
68. Install O-ring seals (33).

Illustration 56 g00890845
Note: Lubricate the piston, and the bore with clean transmission oil.

69. Use Tooling (P) to install piston (31). Install seals (32) on shaft (30).

Illustration 57 g00654029

70. Install spring (29) and retainer (28).

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Illustration 58 g00654018

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.

71. Put the forward low clutch pack in a suitable press. Use Tooling (H) to compress the spring.
Install retaining ring (27).

Illustration 59 g00890608

72. Use a suitable press to install bearing (25). Install retaining ring (26) in hub (22).

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Illustration 60 g00653959
73. Install washer (24).

Illustration 61 g00890607
Note: Refer to Specifications, "Power Shift Transmission" for specifications of clutch discs.

74. Install plates and discs (23). Install hub (21). Install retaining ring (22).

Illustration 62 g00653932

75. Raise the temperature of gear (20). Install gear (20). Install retaining ring (19).

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Illustration 63 g00653893
76. Install washer (18) and retaining ring (17).
Note: This completes the assembly of the forward low gear clutch pack.

Note: Refer to Specifications, "Power Shift Transmission" for the procedure to measure
running clearance.

Illustration 64 g00653858

77. Use Tooling (D) to install the forward low and the forward high clutch pack (15). The weight
of forward high clutch pack (15) is approximately 27 kg (60 lb).
Note: Use Tooling (J) to install plugs (16).

Illustration 65 g00653848

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78. Lower the temperature of bearing cups (14). Use Tooling (K) to install bearing cups (14).

Illustration 66 g00653825

79. Use bolts (12) to install gear (13). Tighten bolts (12) to a torque of 12 ± 3 N·m (10 ± 2 lb ft).

Illustration 67 g00653808

80. Install gear assembly (10).

81. Install O-ring seals (11).

Illustration 68 g00653806

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82. Install bolts (9). Tighten bolts (9) to a torque of 55 ± 10 N·m (40 ± 10 lb ft).

Illustration 69 g00653801

83. ApplyTooling (L) to the seal bore.

84. Install lip seal (7). Lubricate the sealing lip with the lubricant that is being used.

85. Install seal (8).

Illustration 70 g00653775
Note: Lubricate the bore with the lubricant that is being used.

86. Use bolts (5) to install plate (6). Tighten bolts (5) to a torque of 55 ± 10 N·m (40 ± 10 lb ft).

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1/8/23, 10:19 SIS 2.0

Illustration 71 g00657224
87. Clean both mating surfaces of the transmission housing. Apply a continuous bead of Tooling
(N) to the mating surface of the transmission housing.

Illustration 72 g00653680

88. Use Tooling (C) and a suitable lifting device to install the top transmission case. Install bolts
(2). Tighten bolts (2) to a torque of 55 ± 10 N·m (40 ± 10 lb ft). The weight of the top
transmission case is approximately 163 kg (360 lb).

Illustration 73 g03810767
(115) Input shaft assembly
(115B) Cover

89. Install shims (115A) as required to achieve a bearing end play of 0.10 ± 0.05 mm
(0.004 ± 0.002 inch).

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1/8/23, 10:19 SIS 2.0

Illustration 74 g01005187
90. Position the manifold assembly onto the transmission. Install bolts (4E). Install bolts (4D).
Tighten bolts (4D) and (4E) to a torque of 28 ± 7 N·m (21 ± 5 lb ft).

Illustration 75 g01005186

91. Position valve assembly (4C) into the manifold and install bolts (4B).

92. Repeat Step 91 for the remaining valve assemblies.

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PPI SIS 2.0

-
Illustration 76 g01005185

202 0007
93. Connect harness assembly (4A) onto the valve assembly.

14: 3 / 0 C 0FD
1 8/ 0
RE :55- 1
8
N
© 2 R64 04:00
023 22
Cat
erp
illa
r In
Illustration 77 g00671890
Note: Apply Tooling (M) to the threads of bolts (3).

c.
94. Use bolts (3) to install flex plate (4) on torque converter (1). Tighten bolts (3) to a torque of
60 ± 7 N·m (45 ± 5 lb ft).

95. Install torque converter (1).

96. Remove transmission (2) from Tooling (A) and (B). The weight of transmission (2) is
approximately 500 kg (1100 lb).

End By:

a. Install the transmission. Refer to Disassembly and Assembly, "Transmission and Torque
Converter - Install".

PPI-0007C0FD
2023/08/01
14:18:45-04:00
i01932189
© 2023 Caterpillar Inc.

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