Rework Procedure for the Differential on 797 Off-Highway Trucks{3258} Caterpillar


Rework Procedure for the Differential on 797 Off-Highway Trucks{3258}

Usage:

797 5YW
Off-Highway Truck:
797 (S/N: 5YW1-UP)
797B (S/N: JSM1-UP)

Introduction

This Special Instruction provides the information that is necessary to rework the 183-4747 Differential Housing and the 183-4745 Differential Housing for the installation of the new thrust washer.

Reference See 797 Power Train Disassembly and Assembly, "Differential and Bevel Gear Disassembly" for more information about the disassembly process.

Do not perform any procedure that is outlined in this publication or do not order parts until you understand the information that is contained in this document.

Required Parts

Table 1
Required Parts    
Item     Part Number     Description     Qty    
1     309-7670     Thrust Washer     2    

  1. Start by removing the differential and bevel gear.

    Reference See Disassembly and Assembly, "Differential and Bevel Gear - Remove" for more information.

  1. Disassemble the differential and bevel gear.

    Reference See Disassembly and Assembly, "Differential and Bevel Gear - Disassemble" for more information.

Rework Procedure




Illustration 1g01296827

183-4747 Differential Housing

(1) Datum 01




Illustration 2g01296829

273-0356 Differential Housing

(2) 45 degree Chamfer with a depth of 2 mm (0.0787 inch)

(3) 0.8 mm (0.0315 inch) Radius

(A) 120 degrees from the center of the slot to the center of the other slot

(B) 45 degrees from the center of the slot to the lubrication passage

(C) The diameter 220 mm (8.6614 inch) intersects the radius of the slot.

(D) Distance of 182 mm (7.1653 inch) from datum (1) to the bottom of slot

(E) Distance of 168.93 mm (6.6508 inch) from datum (1) to the top surface of slot

  1. Use a 26 mm (1.0236 inch) end cutter with a 0.8 mm (0.0315 inch) radius (3) in order to machine the slots to depth (D) 182 mm (7.1653 inch) from Datum 01 (1). Refer to Illustration 2 in order to view the slot that will be located 45 degree counterclockwise from the lubrication passage and that will be spaced 120 degrees (A) at a diameter of 220 mm (8.6614 inch) (C) to the center point of the radius of the slot. A 2 ± .25 mm (0.0787 ± 0.0098 inch) 45 degree chamfer (2) between the counterbore face and the slot wall is required. Refer to Illustration 2 for 273-0356 Differential Housing . 273-0356 Differential Housing will be machined from the 183-4747 Differential Housing .



    Illustration 3g01296222

    183-4745 Differential Housing Short Half.

    (4) Datum 02




    Illustration 4g01296229

    273-0355 Differential Housing Short Half.

    (5) 45 degree Chamfer with a depth of 2 mm (0.0787 inch)

    (6) 0.8 mm (0.0315 inch) Radius

    (F) 120 degrees from the center of the slot to the center of the other slot

    (G) The diameter 220 mm (8.6614 inch) intersects the radius of the slot.

    (H) Distance of 182 mm (7.1653 inch) from datum (2) to the bottom of slot

    (J) Distance of 168.93 mm (6.6508 inch) from datum (2) to the top surface of slot

  1. Use a 26 mm (1.0236 inch) end cutter with a 0.8 mm (0.0315 inch) radius (6) to machine the slots to depth (H) 182 mm (7.1653 inch) from Datum 02 (4). Slots are to spaced 120 degrees (F) at a diameter of 220 mm (8.6614 inch) (G) to the center point of the radius. A 2 ± 0.25 mm (0.0787 ± 0.0098 inch) 45 degree chamfer (5) between the counterbore face and the slot wall is required.

  1. Assemble the differential and bevel gear.

    Reference See Disassembly and Assembly, "Differential and Bevel Gear - Assemble" for more information.

  1. Install the differential and bevel gear.

    Reference See Disassembly and Assembly, "Differential and Bevel Gear - Install" for more information.

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