D6R2 Track-Type Tractor Power Train Caterpillar

Assembly Procedure

Reference: Refer to Specifications, SENR8324, "Differential Drive and Brake Group"
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Illustration 1	g00824415

1. Install O-ring seal (63) in brake housing (42).

   Note: If bearing cone (65) was removed, a new bearing cone must be installed.

2. Raise the temperature of bearing cone (65).

3. Install bearing cone (65) on housing (41).

4. Lower the temperature of bearing cups (62) and (64).

5. Install bearing cups (62) and (64) in brake housing (42).

   Note: If bearing cone (61) was removed, a new bearing cone must be installed.

6. Raise the temperature of bearing cone (61).

7. Install bearing cone (61) in housing (41).
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   Illustration 2	g01203053

8. Attach a suitable lifting device and Tooling (F) to brake housing (42).

9. Install brake housing (42) onto housing (41). The weight of brake housing (42) is approximately 77 kg (170 lb). The weight of housing (41) is approximately 25 kg (55 lb).
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   Illustration 3	g01203571

10. Install plate (57) and three bolts (56).

11. Install Tooling (K) on plate (57). Do not install the shims at this time.

12. Position brake housing (42) on suitable blocks to raise housing (41) off the floor.

13. Use Tooling (K) to rotate housing (41).

14. Use Tooling (K) to measure the bearing preload. Tighten three bolts (56) equally until the proper preload is reached. The bearing preload should be 3 ± 1 N·m (28 ± 8 lb in).
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    Illustration 4	g00831700

15. When the bearing preload is correct, use a feeler gauge to measure Gap (X) between the housing and plate (57) in three places. Average the three measurements to determine the correct shim pack thickness.

16. Remove three bolts (56) and plate (57).

17. Position correct shims (58) and plate (57) on the housing.

18. Install three bolts (56).

19. Tighten bolts (56) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

20. Use Tooling (K) to recheck the bearing preload.

21. Install three remaining bolts (56).

22. Tighten three remaining bolts (56) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).
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    Illustration 5	g01299036

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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.

23. Install spring (60) and piston (59) in brake housing (42). The spring must be installed with the outer edge downward.
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    Illustration 6	g00824351

24. Install ring seal (55), ring (54), and retainer (53) in brake housing (42).

25. Install bolts (52).
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    Illustration 7	g00824819

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    Illustration 8	g00824349

26. Install thrust washer (51).

27. Install ring (50) in hub (48).

28. Install friction discs and brake plates (49). Install hub (48).

29. Install thrust washer (47). Install retainer (46).

30. Install bolts (45) and the washers.
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    Illustration 9	g01203055

31. Attach Tooling (F) and a suitable lifting device to brake housing (42).

32. Install brake housing (42) in final drive housing (44). The weight of brake housing (42) is approximately 150 kg (335 lb).

33. Install bolts (43).
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    Illustration 10	g00824265

34. Install bevel gear (40) into housing (41).

35. Install bolts (39).

36. Install shims (38) and support bracket (37) in the housing.

37. Install bolts (36).
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    Illustration 11	g00824263

38. Lower the temperature of bearing cups (35).

39. Install bearing cups (35) in planetary carrier (31).
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    Illustration 12	g00831777

40. Raise the temperature of bearing cone (34).

41. Install bearing cone (34) on bevel pinion (27).

42. Raise the temperature of bearing cone (33).

43. Install bevel pinion (27) in planetary carrier (31) and bearing cone (33).
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    Illustration 13	g00831809

44. Install washer (30), lockwasher (29), and nut (28) into the bevel pinion.

45. Position bevel pinion (27) in a soft jawed vise.

46. Use Tooling (C) to tighten nut (28) and preload the bearings.
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    Illustration 14	g01206992

47. Position planetary carrier (31) on two suitable blocks.

48. Use Tooling (K) to measure the bearing preload. The correct bearing preload is 0.80 ± 0.50 N·m (7.000 ± 4.500 lb in).

49. Bend the tang on lock washer (29) in one of the four slots in nut (28).
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    Illustration 15	g00831845

50. Position the bevel pinion and planetary carrier (31) on the support bracket.

51. Install bolt (32).
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    Illustration 16	g01203057

52. Use Tooling (L) to check the backlash of bevel pinion (27). Measure the backlash at three equally spaced teeth on planetary pinion (27). Average the three measurements. The correct backlash is 0.210 ± 0.075 mm (0.0083 ± 0.0030 inch). If necessary, remove support bracket (37) to add or remove shims from shims (38).
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    Illustration 17	g00823872

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    Illustration 18	g00832063

53. Install bearing (25) in planetary gear (22).

54. Position planetary gear (22) and discs (26) in planetary carrier (18).

55. Install shaft (24) in planetary carrier (18).

56. If the rubber in pin (23) is damaged, replace the pin.

57. Align the hole in shaft (24) with the hole in planetary carrier (18).

58. Install pin (23). Install the pin so that the end of the pin is even with the surface of planetary carrier (18).

59. Repeat Steps 53 through 58 for the remaining planetary gears.

60. Install the retaining ring in planetary carrier (18).

61. Connect planetary carrier (18) and ring gear (6).

62. Use Tooling (B) to compress the retaining ring that holds planetary carrier (18) in ring gear (6).

63. Install gear (21), plate (20), and bolts (19) in planetary carrier (18).
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    Illustration 19	g00823759

64. Install spacer (17).

65. Install retaining ring (16), sun gear (15), and lockring (14) into planetary carrier (18).
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    Illustration 20	g00823775

66. Install bearing (13), discs (8), planetary gear (9), and shaft (11) in planetary carrier (7).

67. Use a hammer and a punch to push pin (12) in shaft (11).

68. Install seal ring (10) on planetary carrier (7).
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    Illustration 21	g06187075

69. Install planetary carrier (7), thrust ring (5A), and retaining ring (5) in ring gear (6).

70. Install slinger (4) and two bolts (2) in planetary carrier (7).
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    Illustration 22	g00823691

71. Install Tooling (A) and a suitable lifting device.

72. Install sliding carrier (3). The weight of sliding carrier (3) is approximately 48 kg (105 lb).

73. Remove Tooling (A) and the suitable lifting device.
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    Illustration 23	g00823680

74. Install remaining bolts (2).

75. Install bolts (1) and the washers.

End By:

1. Install the left-hand final drive, the steering differential, and the brake.