980M Tier 4 and 982M Tier 4 Wheel Loaders Power Train Caterpillar

Assembly Procedure

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 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 compressing 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	g06327591

1. Use Tooling (G) to install bearing (143) in the clutch housing. Install the bearing with the notch in the UPWARD position. Install spiral lock (142) in the groove of the clutch housing.
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   Illustration 5	g06327590

2. Install seals (140) and (141) on the clutch piston so that the oil grooves are facing toward the inside the clutch housing. Apply clean transmission oil on the seal rings.
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   Illustration 6	g06327586

3. Install piston (139) and gear (138) in the clutch housing.
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   Illustration 7	g06327896

4. Use Tooling (P) to install bearing (137) in the end of the shaft assembly.
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   Illustration 8	g06327898

5. Raise the temperature of seal carrier (136) to a maximum temperature of 149 °C (300 °F). Install seal carrier (136) on the shaft assembly.
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   Illustration 9	g06327575

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   Illustration 10	g06327574

6. Install O-ring seals (135) on the shaft assembly. Install bearing (134). Use Tooling (L) to install retaining ring (133) onto the shaft assembly.
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   Illustration 11	g06327570

7. Install shaft assembly (132) in shaft assembly (131).
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   Illustration 12	g06327563

8. Install spiral lockring (130) that holds the shaft in position.
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   Illustration 13	g06327558

9. Put the shaft assembly in position on suitable blocks, as shown. Install seals (128) and (129) on the seal carrier. Put a small amount of SAE 30 oil on the seals.

10. Install gear (129) on the shaft assembly.
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    Illustration 14	g06327556

11. Install bearings (119) and (123) in gears (120) and (124).

12. Position thrust discs (118), (121), (122), and (125) on each side of the gears.

13. Position gears (120) and (124) in the carrier and install shaft (126).
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    Illustration 15	g06327548

14. Use a hammer and a punch to install spring pin (117) that holds the shaft in the carrier assembly. Make sure that spring pin (117) is flush with the counterbore in the carrier.

15. Repeat Steps 11 through 14 for the installation of the remaining gears.
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    Illustration 16	g06327544

16. Use Tooling (G) to install bearing (115). Install bearing (115) with the notch in the UPWARD position. Install spiral lockring (114) in the carrier.

17. Install seal rings (116). Apply clean transmission oil on seal rings (116).
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    Illustration 17	g06327543

18. Install retainer ring (113) in the carrier. Compress retainer ring (113) to install gear (112).
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    Illustration 18	g06327541

19. Use two people to install carrier assembly (111) on the shaft assembly. Make sure that the notch in the carrier bearing is in alignment with the dowel in the shaft assembly.
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    Illustration 19	g06327538

20. Install gear (109) and spacer (110) on the shaft assembly.
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    Illustration 20	g06327532

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    Illustration 21	g06327529

21. Install bearing (106) in gear (105).

22. Place thrust discs (104) and (107) on each side of gear (105).

23. Position gear (105) in the carrier. Install shaft (108).

24. Use a hammer and a punch to install the spring pin (103) that holds shaft (108) in the carrier assembly. Make sure that spring pin (103) is flush with the counterbore in the carrier.

25. Repeat Steps 21 through 24 for the installation of the remaining gears.
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    Illustration 22	g06327493

26. Use Tooling (G) to install bearing (100) in the carrier. Install bearing with the notch in the DOWNWARD position. Install seals (101) and (102) and spiral lockring (99).
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    Illustration 23	g06327487

27. Install carrier assembly (98) on the shaft assembly. Align the notch in the bearing with the dowel in the shaft.
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    Illustration 24	g06327483

28. Use Tooling (E) to install retaining ring (96).
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    Illustration 25	g06327481

29. Attach Tooling (C) and a suitable lifting device to output shaft assembly (95). The weight of output shaft assembly (95) and the carrier is approximately 68 kg (150 lb).

30. Put the clutch housing in position on suitable blocks, as shown. Install shaft assembly and carriers in the clutch housing. Make sure that the notch in the bearing is in alignment with the dowel in the carrier assembly.

31. Use Tooling (E) to install the retaining ring (not shown) on the bottom of the carrier assembly.
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    Illustration 26	g06327479

32. Start with a friction disc and install friction discs (93) and clutch plates (94) in the housing.
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    Illustration 27	g06327476

33. Install plate assembly (92) on the housing. Install gear assembly (93).
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    Illustration 28	g06327475

34. Start with a friction disc and install friction discs (89) and clutch plates (90).
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    Illustration 29	g06327461

35. Apply clean transmission oil on seals (87) and (88) and install seal (87) and (88) on the clutch piston.
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    Illustration 30	g06327457

36. Install piston (86) in the housing.
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    Illustration 31	g06327454
    Typical Example

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

37. Install springs (84) and dowels (85).

38. Use Tooling (D) to hold the piston in clutch housing (83). Attach Tooling (B) and a suitable lifting device to clutch housing (83). The weight of clutch housing (83) is approximately 44 kg (97 lb)Install clutch housing (83). Install bolts (82) that hold housing and clutch housing (84) together.
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    Illustration 32	g06327449

39. Install O-ring seal (81) on the shaft assembly.
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    Illustration 33	g06327426

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    Illustration 34	g06327428

40. Install bearing (78) in gear (77).

41. Position thrust discs (76) and (79) on each side of gear (77).

42. Position gear (77) in the carrier. Install shaft (80).

43. Use a hammer and a punch to install spring pin (75) that holds shaft (80) in the carrier assembly. Make sure that spring pin (75) is flush with the counterbore in the carrier assembly.

44. Repeat Steps 40 through 43 for the installation of the remaining gears.
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    Illustration 35	g06327444

45. Use Tooling (G) to install the bearing (74) in the carrier. Install bearing with the notch in the UPWARD position. Install spiral lockring (73).
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    Illustration 36	g06327435

46. Compress the retaining ring and install gear (72).

47. Install the carrier on hub (71). Make sure that the notch in the bearing is in alignment with the dowel on hub (71). Use Tooling (E) to install retaining ring (70) on hub (71).
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    Illustration 37	g06327363
    Typical Example

48. Attach Tooling (B) and a suitable lifting device on carrier (68). The weight of carrier (68) is approximately 32 kg (70 lb). Install carrier (68).
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    Illustration 38	g06327360

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

49. Start with a friction disc and install friction discs (66) and clutch plates (65). Install springs (67).
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    Illustration 39	g06327210

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    Illustration 40	g06327205

50. Install seals (63) and (64) on piston (62). Apply clean transmission oil to the seals. Install piston (62) in the housing.
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    Illustration 41	g06327198
    Typical Example

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

51. Position springs (61).

52. Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to clutch housing (60). The weight of clutch housing (60) is approximately 39 kg (86 lb). Install clutch housing (60).
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    Illustration 42	g06327190

53. Install gear (59).
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    Illustration 43	g06327187

54. Start with a friction disc. Install friction discs (57) and plates (58).
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    Illustration 44	g06327180

55. Install clutch hub (56). Use Tooling (F) to install retaining ring (55).
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    Illustration 45	g06327175

56. Install seals (53) and (54).
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    Illustration 46	g06327172

57. Install piston (52).
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    Illustration 47	g06327170

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

58. Install the plate and three springs (51) into housing. Install plate (50). Use Tooling (H), Tooling (J), and a suitable press to apply force on plate (50) until spiral lockring (49) can be installed.
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    Illustration 48	g06327168

59. If the ring carrier (48) was removed from the housing assembly, heat a new ring carrier to a maximum temperature of 149 °C (300 °F). Install ring carrier (48) and the pin.

60. Install seal rings (47).
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    Illustration 49	g06327069

61. Install clutch housing assembly (46) and retaining ring (45):
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    Illustration 50	g06327064

62. Install seal (43) and (44) onto the clutch piston.
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    Illustration 51	g06327058

63. Install clutch piston (42).

64. Install dowels (41) and rods (40).
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    Illustration 52	g06327052

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

65. Start with a friction disc. Install friction discs (37), clutch plates (38), and springs (39).

66. Install O-ring seal (36).
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    Illustration 53	g01886839

67. Install bearing (35) and retaining ring (34) into the manifold.
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    Illustration 54	g02488916

68. Install O-ring seal (33). Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of manifold assembly (32) is approximately 95 kg (210 lb). Install manifold assembly (32).
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    Illustration 55	g06327045

69. Install bolts (31). Tighten bolts (31) to a torque of 115 ± 7 N·m (85± 5lb ft).

70. Use Tooling (F) to install retaining ring (30).
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    Illustration 56	g06327041

71. Install gear (29).

72. Use Tooling (F) to install retaining ring (28).
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    Illustration 57	g01886833

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    Illustration 58	g01886826

73. Install bearings (24) and (26) in gear (25).

74. Position thrust discs (23) and (27) on each side of the gear (25).

75. Put gears (25) in position in the carrier. Install planetary shafts (21). Make sure that the holes in planetary shafts (21) are in alignment with the holes in the carrier. Install spring pin (22). Make sure that spring pins (22) are flush with the counterbore in the carrier.

76. Repeat Steps 73 through 75 for the installation of the remaining gears.
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    Illustration 59	g01886819

77. Put slinger (20) in position in the carrier. Install locks (18) and bolts (19) that hold the slinger (20) in position. Bend the tabs on locks (18).
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    Illustration 60	g06327038

78. Put carrier assembly (17) in position on the shaft assembly. Install the spacer on the carrier. Use Tooling (E) to install retaining ring (16) on the shaft assembly.
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    Illustration 61	g06327035

79. Install gear (15) on the carrier assembly.
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    Illustration 62	g01886815

80. Install dowels (14) in the manifold assembly.

81. Start with a friction disc and install friction discs (12) and clutch plates (13).
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    Illustration 63	g01886814

82. Install seals (10) on the piston. Apply clean transmission oil to seals (10).

83. Install piston (11) in piston housing (9).
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    Illustration 64	g02505510

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    Illustration 65	g01886812

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

84. Install springs (8). Use Tooling (D) to hold the piston in the housing. Attach Tooling (B) and a suitable lifting device to the housing. The weight of clutch housing (9) is approximately 32 kg (70 lb).

85. Install clutch housing (9). Install bolts (7) that secure the planetary group. Tighten bolts (7) to a torque of 115 ± 7 N·m (85 ± 5 lb ft)
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    Illustration 66	g02505542

86. Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of planetary group (5) is approximately 565 kg (1250 lb). Install planetary group (5) into transmission case (6).
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    Illustration 67	g01915279

87. Install tubes (4) and the O-ring seals.
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    Illustration 68	g01915255

88. Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The weight of modulating valve assembly (2) is approximately 43 kg (95 lb).

89. Install bolts (3).
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    Illustration 69	g01915234

90. Connect tube assembly (1).
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    Illustration 70	g01915213

91. Remove the transmission assembly from Tooling (A).

End By:

1. Connect the transmission and the output transfer gears.