Required Tools | |||
---|---|---|---|
Tool | Part Number | Part Description | Qty |
A | 1U-5750 | Engine Stand | 1 |
1P-2850 | Oil Drain Pan | 1 | |
B | 422-5471 | Lifting Eye Assembly | 2 |
C | 1P-2420 | Transmission Repair Stand | 1 |
D | 469-7625 | Spring Compressor | 1 |
E | - | LOCTITE 243 | - |
F | 369-9451 | Grease | 1 |
G | 466-7458 | Seal Installer | 1 |
H | 466-8474 | Installer | 1 |
J | 501-1553 | Installer | 1 |
K | 469-7618 | Driver | 1 |
For access to a video for this procedure, scan the QR code below with a QR enabled device or copy the link below.
Illustration 1 | g06049267 |
Caterpillar Channel 1 | |
Media Number: | CATU0436 |
Title: | CX-38 Disassembly and Assembly |
Channel 1 URL: | https://channel1.videonitch.com/LearningPrograms/Pass/3383?CategoryID=456 |
- 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.
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Illustration 2 g03850927 - 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).
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Illustration 3 g03851532 - Position a new metal gasket and install housing (165). Install 11 bolts (164).
- Add two bolts 180° apart and tighten by hand.
- Add remaining bolts and tighten by hand.
- Torque bolts to
28 N·m (21 lb ft) in an alternating sequence 180° apart. Then re torque to confirm torque.
- Install new ring seal (166) with the lip (skirt) opening facing down.
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Illustration 4 g03850885 - 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.
- Install seals (160) and (162) and lubricate with the fluid being sealed.
- Install bearing (159) with the orientation marked from the disassembly.
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Illustration 5 g03850908 - Install the ring seals onto shaft (158) and lubricate with the fluid being sealed. Install shaft (158).
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Illustration 6 g03850860 Show/hide tableIllustration 7 g06292825 - 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).
- Install the O-ring seals on high gain piston (157). Lubricate the seals with the fluid being sealed.
- Install pistons (157) and (156).
Note: Align high gain piston (157) dowel with the hole in hub (153).
Show/hide tableIllustration 8 g03850828 - Install 16 springs (154) and 21 springs (155).
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Illustration 9 g03850802 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- Install a new gasket and hub (153). Install 26 bolts (152) and the washers hand tight then torque to standard torque.
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Illustration 10 g03851696 - Install hub assembly (147) and retaining ring (144).
- Install ring seals (146) and lubricate with the fluid being sealed. Install bearing (145) in orientation from the disassembly.
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Illustration 11 g03851981 - Install six clutch No. 6 plates (151) and six friction disks (150) starting with a clutch plate.
- Install end plate (149) with the flat side down and retaining ring (148).
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Illustration 12 g03850700 - Install end clutch plate (143) for clutch No. 1.
Note: Install with ID step facing up.
Show/hide tableIllustration 13 g03850580 - Install hub (142).
- Alternately Install three friction disks (141) and three clutch plates (141) starting with the friction disks. Install the bottom piston clutch retaining ring.
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Illustration 14 g06420096 - 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. - Install sleeve bearing (139B). If necessary use Tooling (K) to install sleeve bearing (139B)
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Illustration 15 g03850519 - 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).
- Install the outer ring seals on piston (134) with the lip (skirt) facing down. (Do not over stretch)
- Lubricate the seals with the fluid being sealed.
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Illustration 16 g03850511 - Install two springs (132) opposite as shown and plate (133).
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Illustration 17 g03850139 Show/hide tableImproper 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.
- Install balance piston (131) and screws (130). Tighten screws (130) to a torque of
12 ± 3 N·m (106 ± 27 lb in) .Note:
- Repeat steps 19 through 24 for the opposite side.
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Illustration 18 g03850542 - Apply Tooling (F) to secure eight thrust buttons (135) to the clutch piston assembly.
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Illustration 19 g03850078 - Install clutch piston assembly (129) with the thrust buttons down. Install top piston clutch retaining ring (128).
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Illustration 20 g03852159 - 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) .Show/hide tableIllustration 21 g03852208 - Install bearing (118) into gear (119).
- Install gear (119) and thrust washers (117) and (120) into the carrier.
- Install shaft (115) into carrier (121).
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Illustration 22 g03852229 - Install spring pin (116) into shaft (115) flush with the carrier assembly.
- Repeat Steps 29 through 32 for the remaining gear assemblies.
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Illustration 23 g03849806 - 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.
- Position retaining ring (111). Compress retaining ring (111) to install gear (112).
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Illustration 24 g03852183 Show/hide tableIllustration 25 g06014133 Show/hide tableIllustration 26 g03874621 - 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.
Show/hide tableIllustration 27 g03852352 - 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.
- Install plastic seals (111a). Lubricate seals (111a) lightly with the lubricant being sealed.
- Install eight thrust buttons (114).
- Alternately Install four clutch No.3 clutch plates (126) and four friction disks (125) starting with clutch plates (126).
- Install end plate (123) (flat side down) and retaining ring (122)
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Illustration 28 g03852481 Show/hide tableIllustration 29 g06038454 - Install the gear and retaining ring (108) into housing (107).
- Install clutch hub (105) and retaining ring (106) on to the hub.
- Install the hub assembly into clutch housing (107).
- Install No. 2 clutch end clutch plate (104).
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Illustration 30 g03849713 - Alternately Install three friction discs (102) and three clutch plates (101) starting with the friction discs.
- Install spring (103).
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Illustration 31 g03849705 - Install retaining ring (99).
- Install the ring seal in clutch piston (100) with the lip facing up.
- Install clutch piston (100).
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Illustration 32 g03852560 Show/hide tableImproper assembly of parts that are spring loaded can cause bodily injury.
To prevent possible injury, follow the established assembly procedure and wear protective equipment.
- 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).
- Use Tooling (D) to compress plate (98). Install retaining ring (96). Slowly decompress Tooling (D) and remove.
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Illustration 33 g03852635 - Use Tooling (F) to secure eight thrust buttons to gear assembly (95).
- Install gear assembly (95) and retaining ring (94).
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Illustration 34 g03852682 - Install clutch assembly (93).
Note: Slowly install clutch assembly over the rotating seals.
Show/hide tableIllustration 35 g03852703 - Position cylinder (90) onto the carrier assembly and install retaining ring (91).
- Install bearing sleeve (84).
- Install bearings (86) and (88) into gear (87).
- Install gear (87) and thrust washers (85) and (89).
- Remove the spring pin from shaft (82) and install shaft (82).
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Illustration 36 g03853089 - Press spring pin (82) into shaft (83) flush with the carrier assembly.
- Repeat Steps 58 through 62 for the remaining gear assemblies.
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Illustration 37 g03853162 - Apply Tooling (F) to secure eight thrust buttons (92) to the carrier assembly.
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Illustration 38 g03853174 - Install carrier assembly (81) and the retaining ring.
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Illustration 39 g03858430 - Apply Tooling (F) to eight thrust buttons (80) and install.
- 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).
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Illustration 40 g03858284 - Install gear (76) and gear assembly (77) as a unit. Install seals (78).
- Lubricate the seals with the lubricant that is being sealed.
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Illustration 41 g06038399 - Install the ring seals onto shaft (74). Install shaft (74).
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Illustration 42 g03849260 - Install a new gasket onto planetary assembly.
- Attach a suitable lifting device to transmission housing (73). The weight of transmission housing (73) is approximately
113 kg (250 lb) . - Remove transmission housing (73) from Tooling (A) and position level onto the planetary assembly.
Note: Location pins line the housing up to the manifold.
Show/hide tableIllustration 43 g03849202 - 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.
Show/hide tableIllustration 44 g03849273 - The combined weight of transmission housing (73) and the planetary assembly is approximately
340 kg (750 lb) . - Remove transmission housing and planetary assembly from Tooling (C) and secure onto Tooling (A).
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Illustration 45 g03849181 - Install intermediate speed sensor assemblies (70) and (72). Install cover (71).
- Install O-ring seals (69).
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Illustration 46 g03849162 - 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).
- Install thrust washer (67).
- Install the assembly into the transmission housing.
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Illustration 47 g03853599 - Install ring gear (61).
- Install six dowel pins (62) and six springs (63).
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Illustration 48 g03853646 - Alternately Install three No. 5 friction disks (65) and three clutch plates (64) stating with the friction discs.
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Illustration 49 g03853681 - Install piston housing (58) and 12 bolts (57).
Note: Orientation of piston housing (58) should be correctly oriented with clutch housing (68).
- Install the ring seals on piston (59) with the lip (skirt) facing down. Lubricate the seals with the fluid being sealed.
- Install piston (59).
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Illustration 50 g03853759 - If necessary, install bearing sleeve (49).
- Install bearings (51) and (53) into gear (52).
- Position thrust washers (50) and (54) and install gear (52).
- Remove spring pin from shaft (47). Install shaft (47) into carrier assembly.
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Illustration 51 g03848983 - Install spring pin (48) into shaft (47) flush with the carrier assembly.
- Repeat 88 Steps 92 through for the remaining gear assemblies.
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Illustration 52 g03848560 - Install retaining ring (46) and compress while installing hub (45).
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Illustration 53 g03853885 - Apply Tooling (F) to secure eight thrust buttons (56) and install thrust buttons (56).
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Illustration 54 g03848531 - 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.
Show/hide tableIllustration 55 g03848519 - Install five dowel pins (41) and plate (43). Install five springs (42).
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Illustration 56 g03848359 - Install two No. 4 clutch plates (40) and three friction discs (39) starting with the friction discs.
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Illustration 57 g03848299 - Install end plate (38) on the next set of splines.
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Illustration 58 g03848079 - 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).
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Illustration 59 g03854289 - Install bearings (31) and (33) into gear (32).
- Install thrust washers (30) and (34) and gear (32).
- Remove the spring pin from shaft (27) and install shaft (27).
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Illustration 60 g03854383 - Install shaft (27). Install spring pin (28) into shaft (27) flush with the inside of the carrier assembly indent.
- Repeat steps 97 through 100 for the remaining gear assemblies.
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Illustration 61 g03847725 - Install rotor sensor (26) and bolts (25).
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Illustration 62 g03847720 - Install bearing (23) and retaining ring (22).
- Install roll pin (24).
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Illustration 63 g03847644 - Install retainer (19) and retaining ring (18).
- Install bearing cone (20) and spacer (21).
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Illustration 64 g03855768 - 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).Show/hide tableIllustration 65 g03847542 - 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.
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Illustration 66 g03855776 - 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.Show/hide tableIllustration 67 g03855813 Note: Installing the yoke assembly will seat the bearing.
- Use Tooling (H) to install wear sleeve (14) onto yoke assembly (11).
- Position yoke assembly (11) and install the two lubricated O-ring seals, the plate, the washer and bolt (13).
- Install output speed sensor assemblies (10).
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Illustration 68 g06045516 - Use Tooling (A) to rotate the transmission 180 degrees.
- Remove bolt (8) and the washers. Ensure bolt (9) is installed and torqued.
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Illustration 69 g03845633 - Install three outside (M12) bolts (6) and the washers.
- Position a new gasket and install cover/manifold (7).
- 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.
Show/hide tableIllustration 70 g03845629 - Install pump (4). Ensure that the pump is fully seated. Install eight bolts (3) and the washers.
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Illustration 71 g03842227 - The torque converter is easier to install with cover (2) removed.
- Install the transmission wiring harness and the associated brackets.
End By:
- Install the torque converter.