Shutdown SIS

Previous Screen

Product: TRUCK
Model: 777D TRUCK AGC
Configuration: 777D Off-Highway Truck AGC00001-UP (MACHINE) POWERED BY 3508B Engine

Disassembly and Assembly

776D Wheeled Tractor and
777D and 777D HAA Off-Highway Trucks Power Train
Media Number -RENR3366-07 Publication Date -01/08/2008 Date Updated -18/08/2008

i07219499

Differential and Bevel Gear - Assemble

SMCS - 3254-016-WH; 3256-016; 3258-016; 3258-016-GE

Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1P-2420 Transmission Repair Stand 1
B FT-1449 Turning Tool 1
D 5P-1730 Holding Fixture 1
E 8T-2843 Spanner Wrench 1
H 1H-3112 Bearing Cup Puller Gp 1
J 5P-7379 Seal Installer 1
- Loctite 263 -
K
- Loctite 270(1) -
L 1P-0520 Driver Gp 1
M FT-0957 Positioning Gp 1
N 8S-2328 Dial Indicator Gp 1
P - Loctite 243 1
(1)
For use in EAME.

Note: Check all the O-ring seals and the components for wear or for damage. Replace the
components, if necessary. Lubricate all the O-ring seals lightly with the lubricant that is being sealed.
Clean all the components with a cloth that is free of loose material (lint).

Illustration 1 g03159397

1. Raise the temperature of bearing cones (41) and (40) to a maximum temperature of 135 °C
(275 °F).

2. Install bearing cones (41) and (40) on pinion assembly (39).

Illustration 2 g06154907

3. Use a suitable press to install wear sleeve (43).

 Illustration 3 g03149916

4. Position the differential carrier assembly on Tooling (A), as shown.

5. Lower the temperature of bearing cup (42) to a maximum of −54 °C (−65 °F). Install bearing
cup (42) into the differential carrier assembly.

Illustration 4 g03150059

6. Use two people to install pinion assembly (39) into the differential carrier assembly (32). The
weight of pinion assembly (39) is approximately 45 kg (100 lb).
 Illustration 5 g03150060

7. Lower the temperature of bearing cup (36) to a maximum of −54 °C (−65 °F). Install bearing
cup (36) in bearing cage (34).

Illustration 6 g03150062

Note: Do not install the O-ring seal or the seal assembly in bearing cage (34) at this time.

8. Position bearing cage (34) on differential carrier assembly (32).

9. Install Tooling (H) into the pinion assembly. Tooling (H) is used to turn the pinion assembly.

10. Install eight of the 16 bolts (33) in bearing cage (34). Rotate the pinion assembly and tighten
bolts (33) evenly until a torque of more than 4 N·m (35 lb in) is needed to rotate the pinion
assembly. Rotate the pinion assembly several times.

11. Tighten bolts (33) evenly as needed to maintain a torque of 4 N·m (35 lb in) to rotate the pinion
assembly.

Note: Seal assembly (35) is not to be installed until after adjustment is made.

12. Measure the gap between bearing cage (34) and differential carrier assembly (32). This
dimension is the correct thickness for the shims that are located between bearing cage (34) and
differential carrier assembly (32). Do not install the shims at this time.

13. Remove bearing cage (34). Do not move the pinion assembly.
 Illustration 7 g03151957

Illustration 8 g03152016

14. Use Tooling (J) to install seal assembly (35). Seal assembly (35) should be oriented with the lip
seal toward Tooling (J).

15. Position bearing cage (34) in a suitable press. Install the seal assembly into bearing cage (34).

Illustration 9 g03153913
16. Install shims (38) that were determined in Step 12.

Illustration 10 g03154136

17. Lubricate seal assembly (35) with the lubricant that is being sealed.

18. Install O-ring seal (37).

Illustration 11 g03154656

19. Attach Tooling (L) and a suitable lifting device (not shown) to bearing cage (34).

20. Install bearing cage (34) on differential carrier assembly (32). Apply Tooling (K) to bolts (33).
Install bolts (33) and the washers. Tighten bolts (33) to a torque of 270 ± 40 N·m
(200 ± 30 lb ft).
 Illustration 12 g00698833

21. Dimension (X) should be 85.17 ± 0.13 mm (3.353 ± 0.005 inch).

 Illustration 13 g03159379

22. Position differential housing assembly (17) on blocks, as shown.

23. Install thrust washer (30) and differential bevel gear (29) in differential housing assembly (17).

Note: Align slots in the thrust washer with the dowels in differential housing assembly (17).

Illustration 14 g03159378

24. Secure Tooling (D) in a suitable vise.

25. Install retainer (26) on Tooling (D). The groove in retainer (26) should be in alignment with the
pin in Tooling (D).

26. Install the nut of Tooling (D).

27. Install bearing cone (28) and spacer (27) on retainer (26).
 Illustration 15 g03159377

28. Position differential pinion (20) in a suitable press. Use Tooling (L) to install bearing cups (25).

Illustration 16 g03159356

29. Install differential pinion (20) on the retainer.

30. Install bearing cone (24).

Illustration 17 g03159337
31. Install nut lock (22) and nut (23).

32. Tighten nut (23) to a torque of 70 ± 15 N·m (52 ± 11 lb ft).

33. Bend the tabs on nut lock (22) to secure nut (24).

34. Remove from Tooling (D).

35. Repeat Steps 24 through 33 for the three remaining differential pinions.

Illustration 18 g03159476

36. Position a suitable lifting device on differential spider (21). Install differential spider (21) and
four differential pinions (23) as an assembly in differential housing assembly (17). Align
grooves in the pinion retainers with the dowels in differential housing assembly (17).

Illustration 19 g03159477

37. Apply grease to the back side of thrust washer (18). Install thrust washer (18) on differential
housing (15). Align grooves in thrust washer (18) with the dowels in differential housing (15).
 Illustration 20 g03159478

38. Install differential and bevel gear (19) on the differential pinions.

39. Install differential housing assembly (15) onto differential housing assembly (17).

Note: There are two types of differentials, refer to the information below:

Illustration 21 g06201259
Differential Type 1 using through bolts with locknuts

a. Install the 8 bolts and the hard washers. Install 8 locknuts (16A). Tighten locknuts (16A)
to a torque of 395 ± 40 N·m (291 ± 30 lb ft).
 Illustration 22 g06201262
Differential Type 2 using bolts without locknuts

b. Use Tooling (P) on bolts (16B). Install the 8 bolts and the hard washers. Tighten bolts
(16B) to a torque of 350 N·m (258 lb ft). Turn the bolts an additional 60 degrees.

Note: Bolts (16B) are one time use only.

Illustration 23 g06237063

40. Support the differential in "V" block type supports.

41. Install Tooling (H) into the differential bevel gear. Turn the gears clockwise by two revolutions.
Turn the gears counterclockwise by two revolutions. The maximum torque that is required to
turn the gears must not exceed 35 N·m (26 lb ft). If the maximum torque that is required to turn
the gears is more than 35 N·m (26 lb ft), the differential must be reassembled.
 Illustration 24 g03159496

42. Position differential and bevel gear (12) on suitable blocks, as shown.

Note: Check the bolts for wear. If necessary, use new bolts.

Illustration 25 g03160478

43. Prior to assembling the differential group, assemble ring gear (12) to the housing. Use the ring
gear as a guide and ream one hole to a diameter of 19.0500 ± 0.0130 mm
(0.75000 ± 0.00051 inch). Assemble one bolt and ream 13 holes to a diameter of
19.05 ± 0.013 mm (0.75000 ± 0.00051 inch). Install the remainder of the bolts. Install washers
(14) and locknuts (13). Tighten the nuts to a torque of 440 ± 40 N·m (325 ± 30 lb ft).
 Illustration 26 g03154656

44. Attach Tooling (L) and a suitable lifting device (not shown) to bearing cage (34).

45. Install bearing cage (34) on differential carrier assembly (32). Apply Tooling (K) to bolts (33).
Install bolts (33) and the washers. Tighten bolts (33) to a torque of 270 ± 40 N·m
(200 ± 30 lb ft).

Illustration 27 g03159516

46. Raise the temperature of bearing cone (11) to a maximum temperature of 135 °C (275 °F).

47. Install bearing cone (11) onto the differential. Bearing cone (11) must touch flat surface of
surface differential housing assembly (38).
 Illustration 28 g03159517

48. Turn over the differential. Raise the temperature of bearing cone (10) to a maximum
temperature of 135 °C (275 °F).

49. Install bearing cone (10) onto the differential. Bearing cone (10) must touch the shoulder of the
differential.

Illustration 29 g03158820

50. Use a suitable press to install bearing cups (9) into bearing cages (7).
 Illustration 30 g03159519

51. Position a suitable lifting device on the differential. The weight of the differential is
approximately 249 kg (550 lb). Install bearing cages (7) on the differential. Install the bearing
cages (7) with the dowel holes in the up position.

52. Lower the differential to the differential carrier assembly. Do not rest the differential on the
differential carrier assembly.

53. Install one adjustment ring (8) on each end of the differential. Do not tighten adjustment rings
(8) at this time.

Illustration 31 g03158187

54. Install bearing caps (6) and (5). The dowels must align with the holes in bearing cages (7).

55. Install the washers and the bolts that secure bearing caps (6) and (5). Do not tighten the bolts to
full torque.

Illustration 32 g03159536

56. Use Tooling (N) to attach the differential and bevel gear to Tooling (A). The teeth of the
differential bevel gear must be positioned in the up position.
57. Position Tooling (M) on the differential carrier assembly, as shown.

58. Use Tooling (B) (not shown) to tighten the bottom adjustment ring until a backlash of
0.410 ± 0.130 mm (0.0161 ± 0.0051 inch) exists between the differential bevel gear and the
pinion assembly.

Illustration 33 g06256303

59. Position Tooling (M) (not shown) on the differential carrier assembly.

60. Use Tooling (B) to adjust the top adjustment ring so that dimension (Z) increases by
0.64 to 0.76 mm (0.025 to 0.030 inch).

61. Rotate the differential bevel gear by several revolutions in each direction.

62. Use Tooling (B) to loosen the top adjustment ring so that no tension is on the bearings.

63. Use Tooling (B) to adjust the top adjustment ring so that dimension (Z) increases by
0.51 ± 0.05 mm (0.020 ± 0.002 inch).
 Illustration 34 g03159536

64. Position Tooling (M), as shown. Measure the backlash from the differential bevel gear to the
pinion assembly. If the measurement is not equal to 0.410 ± 0.130 mm (0.0161 ± 0.0051 inch),
then adjustment is required. Adjust the adjustment rings equally. If the top adjustment ring is
loosened, the bottom adjustment ring should be tightened by the same amount. If the adjustment
rings are not adjusted equally, then the bearing preload will be incorrect.

Illustration 35 g03159539

65. Tighten bolts (3) to a torque of 1100 ± 150 N·m (810 ± 110 lb ft).

Illustration 36 g03157537

66. Install locks (2), the washers, and bolts (1) on the bearing caps.

End By:

a. Install the differential and bevel gear. Refer to Disassembly and Assembly, "Differential and
Bevel Gear - Install".

Wed Jul 22 11:47:13 UTC+0530 2020

Copyright 1993 - 2020 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.