735C, 740C EJECTOR and 745C Articulated Trucks Power Train Caterpillar


Transmission Planetary - Assemble

Usage:

735C LFJ


Assembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
1U-5750  Engine Stand 
1P-2850 Oil Drain Pan 
422-5471  Lifting Eye Assembly 
1P-2420  Transmission Repair Stand 
469-7625  Spring Compressor 
LOCTITE 243 
369-9451  Grease 
466-7458  Seal Installer 
466-8474  Installer 
501-1553  Installer 
469-7618  Driver 

For access to a video for this procedure, scan the QR code below with a QR enabled device or copy the link below.



Illustration 1g06049267

Table 2
Caterpillar Channel 1 
Media Number:  CATU0436 
Title:  CX-38 Disassembly and Assembly 
Channel 1 URL:  https://channel1.videonitch.com/LearningPrograms/Pass/3383?CategoryID=456 

  1. Replace all gaskets and inspect O-ring seals for serviceability. Check for breaks and creases in all gaskets and indentations in the metal gaskets. Replace if necessary. Replace O-ring seals if necessary.


    Illustration 2g03850927

  2. Position a new metal gasket under hub assembly with raised geometry facing up. Install the O-ring seal on to the hub assembly. Install hub assembly (167).


    Illustration 3g03851532

  3. Position a new metal gasket and install housing (165). Install 11 bolts (164).

    1. Add two bolts 180° apart and tighten by hand.

    2. Add remaining bolts and tighten by hand.

    3. Torque bolts to 28 N·m (21 lb ft) in an alternating sequence 180° apart. Then re torque to confirm torque.

  4. Install new ring seal (166) with the lip (skirt) opening facing down.


    Illustration 4g03850885

  5. Install roller bearing inside housing (163) so it is flush with the top of the housing. Position a new gasket and install housing (163). Install two M8 and six M10 bolts (161) and the thin washers.

    Note: Do not substitute washers as interference will occur.

  6. Install seals (160) and (162) and lubricate with the fluid being sealed.

  7. Install bearing (159) with the orientation marked from the disassembly.


    Illustration 5g03850908

  8. Install the ring seals onto shaft (158) and lubricate with the fluid being sealed. Install shaft (158).


    Illustration 6g03850860


    Illustration 7g06292825

  9. Install the O-ring seal and ring seals on low gain piston (156). Install the lip (skirt) opening facing down on low gain piston (156).

  10. Install the O-ring seals on high gain piston (157). Lubricate the seals with the fluid being sealed.

  11. Install pistons (157) and (156).

    Note: Align high gain piston (157) dowel with the hole in hub (153).



    Illustration 8g03850828

  12. Install 16 springs (154) and 21 springs (155).


    Illustration 9g03850802

    ------ WARNING! ------

    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.


  13. Install a new gasket and hub (153). Install 26 bolts (152) and the washers hand tight then torque to standard torque.


    Illustration 10g03851696

  14. Install hub assembly (147) and retaining ring (144).

  15. Install ring seals (146) and lubricate with the fluid being sealed. Install bearing (145) in orientation from the disassembly.


    Illustration 11g03851981

  16. Install six clutch No. 6 plates (151) and six friction disks (150) starting with a clutch plate.

  17. Install end plate (149) with the flat side down and retaining ring (148).


    Illustration 12g03850700

  18. Install end clutch plate (143) for clutch No. 1.

    Note: Install with ID step facing up.



    Illustration 13g03850580

  19. Install hub (142).

  20. Alternately Install three friction disks (141) and three clutch plates (141) starting with the friction disks. Install the bottom piston clutch retaining ring.


    Illustration 14g06420096

  21. Install pin (138). Apply Tooling (E) to the threads of set screw (137). Install and tighten set screw (137) to a torque of 12 ± 3 N·m (106 ± 27 lb in). Repeat for the opposite side.

  22. Install sleeve bearing (139B). If necessary use Tooling (K) to install sleeve bearing (139B)


    Illustration 15g03850519

  23. Install the inner ring seal. and outer ring seals on piston (134). Install the outer ring seal with the lip facing towards the housing. Install piston (134).

  24. Install the outer ring seals on piston (134) with the lip (skirt) facing down. (Do not over stretch)

  25. Lubricate the seals with the fluid being sealed.


    Illustration 16g03850511

  26. Install two springs (132) opposite as shown and plate (133).


    Illustration 17g03850139

    ------ WARNING! ------

    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.


    Note: Start with four screws located 90 degrees apart from each other and snug them up until just contacting the piston by hand without compressing the piston. Then tighten further down alternating across 180 degrees from each other to slowly compress the springs. Progressing too much at a time will cause the springs to slide, thus causing the piston to cock one side. Once the piston has bottomed out, the edge of the piston will be flush to the top of the housing. Install the remaining bolts and torque all bolts to specification.

  27. Install balance piston (131) and screws (130). Tighten screws (130) to a torque of 12 ± 3 N·m (106 ± 27 lb in).

    Note:

  28. Repeat steps 19 through 24 for the opposite side.


    Illustration 18g03850542

  29. Apply Tooling (F) to secure eight thrust buttons (135) to the clutch piston assembly.


    Illustration 19g03850078

  30. Install clutch piston assembly (129) with the thrust buttons down. Install top piston clutch retaining ring (128).


    Illustration 20g03852159

  31. Remove two bolts 180° apart from the piston assembly and attach a suitable lifting device. Install hub assembly (127) and O-ring seals (124). Lubricate O-ring seals (124) lightly with lubricant that is being sealed. Tighten the bolts removed from the piston assembly to a torque of 12 ± 3 N·m (106 ± 27 lb in).


    Illustration 21g03852208

  32. Install bearing (118) into gear (119).

  33. Install gear (119) and thrust washers (117) and (120) into the carrier.

  34. Install shaft (115) into carrier (121).


    Illustration 22g03852229

  35. Install spring pin (116) into shaft (115) flush with the carrier assembly.

  36. Repeat Steps 29 through 32 for the remaining gear assemblies.


    Illustration 23g03849806

  37. Install ring seals (113). Apply Tooling (F) to the grooves and ring seals (113) to keep the seals secure to the carrier assembly when installing.

    Note: Tooling (F) is critical in preventing damage to seals (113) during the carrier installation.

  38. Position retaining ring (111). Compress retaining ring (111) to install gear (112).


    Illustration 24g03852183


    Illustration 25g06014133


    Illustration 26g03874621

  39. Position carrier assembly (109). Install Tooling (J) on to carrier assembly (109). Turn the latch 1/4 turn to lock the latch. Screw Tooling (J) to the carrier. Turn the handles evenly until the carrier bottoms out and the retaining ring groove becomes visible. The groove will be slightly recessed.

    Note: Even downward pressure will prevent seals (113) from dislodging from the carrier.



    Illustration 27g03852352

  40. Position retaining ring (110) over shaft next to the groove.

    Note: Lifting slightly on the center shaft from the bottom will allow the retaining ring to be installed in to the groove. Slightly tap the retaining ring in place. Do not lift on the center shaft by installing and eye bolt on top as damage may occur to the shaft.

  41. Install plastic seals (111a). Lubricate seals (111a) lightly with the lubricant being sealed.

  42. Install eight thrust buttons (114).

  43. Alternately Install four clutch No.3 clutch plates (126) and four friction disks (125) starting with clutch plates (126).

  44. Install end plate (123) (flat side down) and retaining ring (122)


    Illustration 28g03852481


    Illustration 29g06038454

  45. Install the gear and retaining ring (108) into housing (107).

  46. Install clutch hub (105) and retaining ring (106) on to the hub.

  47. Install the hub assembly into clutch housing (107).

  48. Install No. 2 clutch end clutch plate (104).


    Illustration 30g03849713

  49. Alternately Install three friction discs (102) and three clutch plates (101) starting with the friction discs.

  50. Install spring (103).


    Illustration 31g03849705

  51. Install retaining ring (99).

  52. Install the ring seal in clutch piston (100) with the lip facing up.

  53. Install clutch piston (100).


    Illustration 32g03852560

    ------ WARNING! ------

    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.


  54. Install the ring seal on plate (98) with the lip facing down. Lubricate the O-ring seal and shaft lightly with lubricant that is being sealed. Install the O-ring seal and plate (98).

    Note: Do not use old retaining ring (96). Install a new retaining ring (96).

  55. Use Tooling (D) to compress plate (98). Install retaining ring (96). Slowly decompress Tooling (D) and remove.


    Illustration 33g03852635

  56. Use Tooling (F) to secure eight thrust buttons to gear assembly (95).

  57. Install gear assembly (95) and retaining ring (94).


    Illustration 34g03852682

  58. Install clutch assembly (93).

    Note: Slowly install clutch assembly over the rotating seals.



    Illustration 35g03852703

  59. Position cylinder (90) onto the carrier assembly and install retaining ring (91).

  60. Install bearing sleeve (84).

  61. Install bearings (86) and (88) into gear (87).

  62. Install gear (87) and thrust washers (85) and (89).

  63. Remove the spring pin from shaft (82) and install shaft (82).


    Illustration 36g03853089

  64. Press spring pin (82) into shaft (83) flush with the carrier assembly.

  65. Repeat Steps 58 through 62 for the remaining gear assemblies.


    Illustration 37g03853162

  66. Apply Tooling (F) to secure eight thrust buttons (92) to the carrier assembly.


    Illustration 38g03853174

  67. Install carrier assembly (81) and the retaining ring.


    Illustration 39g03858430

  68. Apply Tooling (F) to eight thrust buttons (80) and install.

  69. Install the O-ring seals and ring seal onto gear (76). Lubricate the seals with the fluid that is being sealed. Install gear (76) and retaining ring (79) onto gear assembly (77).


    Illustration 40g03858284

  70. Install gear (76) and gear assembly (77) as a unit. Install seals (78).

  71. Lubricate the seals with the lubricant that is being sealed.


    Illustration 41g06038399

  72. Install the ring seals onto shaft (74). Install shaft (74).


    Illustration 42g03849260

  73. Install a new gasket onto planetary assembly.

  74. Attach a suitable lifting device to transmission housing (73). The weight of transmission housing (73) is approximately 113 kg (250 lb).

  75. Remove transmission housing (73) from Tooling (A) and position level onto the planetary assembly.

    Note: Location pins line the housing up to the manifold.



    Illustration 43g03849202

  76. Install bolt (8) with one washer and bolt (9) with three washers.

    Note: Failure to install bolts (8) and (9) will result in the planetary failing out when rotating.



    Illustration 44g03849273

  77. The combined weight of transmission housing (73) and the planetary assembly is approximately 340 kg (750 lb).

  78. Remove transmission housing and planetary assembly from Tooling (C) and secure onto Tooling (A).


    Illustration 45g03849181

  79. Install intermediate speed sensor assemblies (70) and (72). Install cover (71).

  80. Install O-ring seals (69).


    Illustration 46g03849162

  81. Install the ID and OD ring seals on piston (66) with the lip (skirt) facing down. Lubricate the seals with the lubricate being sealed. Install piston (66) into clutch housing (68).

  82. Install thrust washer (67).

  83. Install the assembly into the transmission housing.


    Illustration 47g03853599

  84. Install ring gear (61).

  85. Install six dowel pins (62) and six springs (63).


    Illustration 48g03853646

  86. Alternately Install three No. 5 friction disks (65) and three clutch plates (64) stating with the friction discs.


    Illustration 49g03853681

  87. Install piston housing (58) and 12 bolts (57).

    Note: Orientation of piston housing (58) should be correctly oriented with clutch housing (68).

  88. Install the ring seals on piston (59) with the lip (skirt) facing down. Lubricate the seals with the fluid being sealed.

  89. Install piston (59).


    Illustration 50g03853759

  90. If necessary, install bearing sleeve (49).

  91. Install bearings (51) and (53) into gear (52).

  92. Position thrust washers (50) and (54) and install gear (52).

  93. Remove spring pin from shaft (47). Install shaft (47) into carrier assembly.


    Illustration 51g03848983

  94. Install spring pin (48) into shaft (47) flush with the carrier assembly.

  95. Repeat 88 Steps 92 through for the remaining gear assemblies.


    Illustration 52g03848560

  96. Install retaining ring (46) and compress while installing hub (45).


    Illustration 53g03853885

  97. Apply Tooling (F) to secure eight thrust buttons (56) and install thrust buttons (56).


    Illustration 54g03848531

  98. Orient carrier assembly as shown. Attach Tooling (B) and a suitable lifting device to carrier assembly (44). The weight of carrier assembly (44) is approximately 34 kg (75 lb). Install carrier assembly (44).

    Note: If carrier assembly (44) does not seat properly, check for proper thrust button installation.



    Illustration 55g03848519

  99. Install five dowel pins (41) and plate (43). Install five springs (42).


    Illustration 56g03848359

  100. Install two No. 4 clutch plates (40) and three friction discs (39) starting with the friction discs.


    Illustration 57g03848299

  101. Install end plate (38) on the next set of splines.


    Illustration 58g03848079

  102. Install retaining ring (36). Compress retaining ring (36) and install gear (37). Apply Tooling (F) to thrust buttons (35) and install eight thrust buttons (35).


    Illustration 59g03854289

  103. Install bearings (31) and (33) into gear (32).

  104. Install thrust washers (30) and (34) and gear (32).

  105. Remove the spring pin from shaft (27) and install shaft (27).


    Illustration 60g03854383

  106. Install shaft (27). Install spring pin (28) into shaft (27) flush with the inside of the carrier assembly indent.

  107. Repeat steps 97 through 100 for the remaining gear assemblies.


    Illustration 61g03847725

  108. Install rotor sensor (26) and bolts (25).


    Illustration 62g03847720

  109. Install bearing (23) and retaining ring (22).

  110. Install roll pin (24).


    Illustration 63g03847644

  111. Install retainer (19) and retaining ring (18).

  112. Install bearing cone (20) and spacer (21).


    Illustration 64g03855768

  113. Attach a suitable lifting device to carrier assembly (15). The weight of carrier assembly (15) is approximately 36 kg (80 lb). Install carrier assembly (15).


    Illustration 65g03847542

  114. Install two bearing cups and bearing cone (17). Use Tooling (G) to install new lip seal (16) Lubricate the seals with the fluid that in being sealed.


    Illustration 66g03855776

  115. Position a new gasket and install the rear cover assembly. Install 24 bolts (12) and the washers.

    Note: Prior to tightening bolts (12) there will be a minimum 5 mm (0.2 inch) between the rear cover and the case.



    Illustration 67g03855813

    Note: Installing the yoke assembly will seat the bearing.

  116. Use Tooling (H) to install wear sleeve (14) onto yoke assembly (11).

  117. Position yoke assembly (11) and install the two lubricated O-ring seals, the plate, the washer and bolt (13).

  118. Install output speed sensor assemblies (10).


    Illustration 68g06045516

  119. Use Tooling (A) to rotate the transmission 180 degrees.

  120. Remove bolt (8) and the washers. Ensure bolt (9) is installed and torqued.


    Illustration 69g03845633

  121. Install three outside (M12) bolts (6) and the washers.

  122. Position a new gasket and install cover/manifold (7).

  123. Install bolts (5) and the washers a torque to 63 ± 2 N·m (46 ± 1.5 lb ft).

    Note: Note the length of the cover/manifold bolts.



    Illustration 70g03845629

  124. Install pump (4). Ensure that the pump is fully seated. Install eight bolts (3) and the washers.


    Illustration 71g03842227

  125. The torque converter is easier to install with cover (2) removed.

  126. Install the transmission wiring harness and the associated brackets.

End By:

  1. Install the torque converter.

Caterpillar Information System:

735C, 740C EJECTOR and 745C Articulated Trucks Power Train Transmission Planetary - Disassemble
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