Pruebas y Ajuste Tren de Potencia RENR2506!05!01-PT

RENR2506-05
December 2002
Testing and Adjusting

994D Wheel Loader
Power Train
3TZ1-Up (Machine)
i01658146
Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or
pictorially presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure,
work method or operating technique that is not specifically recommended by Caterpillar is used,
you must satisfy yourself that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
3
Power Train
Table of Contents
Table of Contents
Testing and Adjusting Section
Troubleshooting
General Information .............................................. 4
Machine Preparation for Troubleshooting ............. 5
Visual Inspection ................................................... 6
Torque Converter Troubleshooting ........................ 8
Transmission Troubleshooting ............................... 12
Differential and Final Drive Troubleshooting ......... 19

Torque Converter Inlet Pressure - Test ................. 21
Torque Converter Outlet Pressure - Test .............. 22
Torque Converter Impeller Clutch Pressure -
Test ..................................................................... 25
Torque Converter Lockup Clutch Pressure - Test .. 29
Reduced Rimpull Pressure - Test ......................... 33
Torque Converter Stall - Test ................................ 36
Transmission Pressures - Test and Adjust ............ 37
Solenoid Valve (Transmission Clutch) - Test ......... 42
Speed Sensor (Transmission Output) - Adjust ...... 45
Limit Switch (STIC Control Lock) - Adjust ............. 46
Bearing End Play (Rear Pump Drive) - Adjust ...... 47
Bearing End Play (Drive Shaft Support) - Adjust .. 49
Input Transfer Gears - Adjust ................................ 50
Output Transfer Gears - Adjust ............................. 50
Differential Pinion Preload - Adjust ....................... 54
Differential Backlash and Bearings - Adjust .......... 56
Wheel Bearings - Adjust ....................................... 59
Index Section
Index ..................................................................... 61
4
Power Train

Section Escaping fluid under pressure, even a pinhole size
leak, can penetrate body tissue, causing serious
injury, and possible death. If fluid is injected into
Troubleshooting your skin, it must be treated immediately by a doc-
tor familiar with this type of injury.
i01397515 Always use a board or cardboard when checking

for a leak.
General Information
SMCS Code: 3000-035 NOTICE
Care must be taken to ensure that fluids are contained
Refer to the following warnings and the notice for during performance of inspection, maintenance, test-
all inspections and tests of the power train. If the ing, adjusting and repair of the product. Be prepared to
source of the problem is not determined, perform collect the fluid with suitable containers before open-
the inspections and tests. Perform the inspections ing any compartment or disassembling any compo-
and tests in sequential order. For all tests, the power nent containing fluids.
train oil must be at normal operating temperature.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Sudden movement of the machine or release of oil
under pressure can cause injury to persons on or Dispose of all fluids according to local regulations and
near the machine. mandates.
To prevent possible injury, perform the procedure
that follows before testing and adjusting the pow- When a power train problem is being defined, the
er train. following procedure should be used.
Note: This machine is equipped with a power train

electronic control module (ECM). The power train
ECM is equipped with built-in diagnostics that
Personal injury can result from hydraulic oil pres- detect faults in the electronic system of the power
sure and hot oil. train.
Hydraulic oil pressure can remain in the hydraulic 1. Use the built-in electrical diagnostics that are
system after the engine has been stopped. Seri- performed with the Vital Information Management
ous injury can be caused if this pressure is not re- System (VIMS) and with the power train ECM in
leased before any service is done on the hydraulic order to check for any active service codes for
system. the power train ECM.
Make sure all of the attachments have been low- Reference: For more information on the
ered, oil is cool before removing any components diagnostic procedures for the power train ECM,
or lines. Remove the oil filler cap only when the en- refer to the Service Manual module Systems
gine is stopped, and the filler cap is cool enough Operation, Testing and Adjusting, RENR2522,
to touch with your bare hand. “Power Train Electronic Control System”.
Reference: For more information on the

diagnostic procedures for the Vital Information
Management System (VIMS), refer to the
Service Manual, SENR6059, “Vital Information
Management System (VIMS)”.
5
Power Train
2. Perform visual checks. If the visual checks

are completed but the problem has not been
identified, perform operational checks. If the
Personal injury can result from hydraulic oil pres-
problem is not understood, perform instrument
sure and hot oil.
tests. This procedure will help to identify power
train problems.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Seri-
3. When the problem has been specifically identified
ous injury can be caused if this pressure is not re-
as coming from a power train component, refer
leased before any service is done on the hydraulic
to the following topics for the probable causes
system.
of a known problem. Testing and Adjusting,
“Torque Converter Troubleshooting”, Testing and
Make sure all of the attachments have been low-
Adjusting, “Transmission Troubleshooting”, and
ered, oil is cool before removing any components
Testing and Adjusting, “Differential and Final
or lines. Remove the oil filler cap only when the en-
DriveTroubleshooting”.
gine is stopped, and the filler cap is cool enough
to touch with your bare hand.
4. There may be more than one cause for a
problem. The Service Manual module Testing
and Adjusting, RENR2506 may suggest specific
inspections or specific instrument tests that
should be performed.
Escaping fluid under pressure, even a pinhole size
Note: The inspections and the tests that are found injury, and possible death. If fluid is injected into
in the reference literature will help to identify the
your skin, it must be treated immediately by a doc-
most probable causes of a problem. The reference
literature cannot include all of the possible problems
and all of the corrections. The service personnel
Always use a board or cardboard when checking
must find the problem and the source of the
for a leak.
problem. Then, the necessary repairs can be made.
i01397904
NOTICE
Machine Preparation for during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Troubleshooting collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
SMCS Code: 3000-035 nent containing fluids.
Refer to the following warnings and the notice for Refer to Special Publication, NENG2500, “Caterpillar
all inspections and tests of the power train. If the Tools and Shop Products Guide” for tools and supplies
source of the problem is not determined, perform suitable to collect and contain fluids on Caterpillar
the inspections and tests. Perform the inspections products.
and tests in sequential order. For all tests, the power
train oil must be at normal operating temperature. Dispose of all fluids according to local regulations and
mandates.
1. Move the machine to a smooth, horizontal

Sudden movement of the machine or release of oil location that is away from operating machines
under pressure can cause injury to persons on or and away from personnel.
near the machine.
Note: Permit only one operator on the machine.
To prevent possible injury, perform the procedure Keep all other personnel away from the machine
that follows before testing and adjusting the pow- or in the operator’s sight.
er train.
2. Move the STIC transmission direction control
switch to the NEUTRAL position. Move the STIC
control lock into the LOCKED position.
3. Move the work tool until the bottom of the work

tool is 1.2 m (4 ft) above the ground. Position the
work tool so that the cutting edge points down
approximately 20 degrees below horizontal.
6
Power Train
4. Lower the work tool until the cutting edge of the i01398245
work tool is just off of the ground.
Visual Inspection
5. Turn the key switch to the OFF position in order
to shut off the engine. SMCS Code: 3000-035
6. Move both the lift control lever and the tilt control
lever to all positions in order to release the
pressure in the hydraulic system. Sudden movement or accidental starting of the
machine can cause personal injury or death to per-
7. Place the lift control lever into the FLOAT position sons on or near the machine.
and the tilt control lever into the HOLD position.
To prevent personal injury or death, perform the
8. Release the pressure in the implement hydraulic following:
tank. Depress the plunger on the hydraulic tank
breather until air no longer escapes. Loosen the Park the machine on a smooth level surface.
oil filler cap for the implement tank until air no
longer escapes. Tighten the filler cap. Lower the bucket and or attachments to the
ground.
9. Engage the parking brake.
Stop the engine and engage the parking brake.
10. Put blocks in front of the wheels and behind the
wheels. Block the wheels and install the steering frame
lock.
11. Install the steering frame lock.
Turn the battery disconnect switch to the OFF po-
Troubleshooting can be complex. A list of some of sition and remove the key.
the possible problems and corrections are on the
following pages. Place a Special Instruction, SEHS7332, “Do Not
Operate” tag at the battery disconnect switch lo-
This list of possible problems and possible cation to inform personnel that the machine is be-
corrections will only provide an indication of ing worked on.
the location of a problem and the repairs that
are required. Remember that a problem is not
necessarily caused by one part, but by the relation
of one part with other parts. This list can not provide
all possible problems and corrections. Service Personal injury can result from hydraulic oil pres-
personnel must find the problem and the source of sure and hot oil.
the problem. Then, complete the necessary repairs.
Perform a visual inspection first. If the visual system after the engine has been stopped. Seri-
checks are completed but the problem has not ous injury can be caused if this pressure is not re-
been identified, perform operational checks. If the leased before any service is done on the hydraulic
problem is not understood, perform instrument system.
tests. This procedure will help to identify power train
problems. Make sure all of the attachments have been low-
7
Power Train
a. Air bubbles may be caused by a fitting that is

loose or damaged. A loose fitting or damaged
fitting allows air to enter the suction side of the
system and oil is also allowed to leak. Also, if
the transmission oil level is too high and the
gears are agitating the oil in the sump, air
bubbles may result.
b. A leaking transmission oil cooler may cause
coolant to enter the system. Water may enter
for a leak.
the system if the filler cap or the dipstick is
not properly installed.
NOTICE
Care must be taken to ensure that fluids are contained 3. Check all oil lines, all hoses, and all connections
during performance of inspection, maintenance, test- for damage and for leaks. Look for oil on the
ing, adjusting and repair of the product. Be prepared to ground under the machine.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Note: If oil can leak out of a fitting or out of a
nent containing fluids. connection, air can leak into the system. Air in the
system is as harmful as having too little oil.
Tools and Shop Products Guide” for tools and supplies 4. Remove the drain plug in the bottom of the
suitable to collect and contain fluids on Caterpillar output transfer gear case in order to drain the
products. oil from the transmission. Remove the suction
screen and clean the suction screen. Inspect the
Dispose of all fluids according to local regulations and oil and the suction screen for foreign material.
mandates. Remove the transmission oil filter and inspect
the filter for foreign material. (Cut the filter open,
if necessary.)
Note: If the machine will not move, check the
fuse for the power train electronic control module Note: There is an oil filter bypass valve on the inlet
(ECM). The fuse panel is located in the electronics side of the transmission oil filter. Whenever the
compartment on the right side of the cab platform. pressure difference between the inlet oil and the
Open the access door on the right side of the cab outlet oil is more than 345 ± 21 kPa (50 ± 3 psi),
platform in order to access the fuse panel. the bypass valve will open and oil will be allowed
to bypass the oil filter element. Any oil that does
Perform visual checks first when you are not flow through the oil filter element flows directly
troubleshooting a problem. Before you make these into the hydraulic control circuit. This dirty oil can
checks, stop the engine and engage the parking cause valves to become stuck and valve orifices
brake. Shift the STIC transmission direction control could become restricted.
switch to the NEUTRAL position. During these
checks, use a magnet to separate ferrous particles a. Rubber particles indicate a seal failure or a
(iron) from nonferrous particles (O-ring seals, hose failure.
aluminum, bronze, etc), if necessary.
b. Shiny steel particles indicate a mechanical
1. Check the oil level in the differentials. failure or gear wear of the transmission or of a
pump.
2. Check the transmission oil level. Look for air
bubbles in the oil or water in the oil. Many c. A thick accumulation of fibrous material
problems in the transmission are caused by indicates worn clutch discs in the
low oil level or by air in the oil. Add oil to the transmission.
transmission, if necessary. Refer to the Operation
and Maintenance Manual, “Lubricant Viscosities d. Aluminum particles indicate torque converter
and Refill Capacities” for the recommended oil wear or a torque converter failure.
grade and the recommended oil viscosity for the
machine that is being serviced. e. Iron particles or steel particles indicate broken
components in the transmission.
Note: If any of these particles are found during any

visual check, all components of the transmission
hydraulic system must be cleaned. Do not use
any damaged parts. Any damaged parts must be
removed and new parts must be installed.
8
Power Train
5. The drive shafts and universal joints must rotate

freely unless cold oil is causing a resistance. If
the drive shafts do not turn freely, disconnect
the drive shafts and check that the transmission
will turn.
i01398906
Torque Converter
Troubleshooting
SMCS Code: 3101-035
9
Power Train
g00790887
Illustration 1
Power Train Hydraulic Schematic
(The Transmission is in NEUTRAL and the Engine is Stopped.)
10
Power Train
(1) Number 2 Clutch Solenoid (17) Impeller Clutch (30) Lubrication Passage for the
(2) Number 3 Clutch Solenoid (18) Speed Selector Spool (First Speed and Transmission
(3) Priority Valve Third Speed) (31) Reservoir
(4) Number 1 Clutch Solenoid (19) Pressure Differential Valve (32) Reservoir
(5) Number 5 Clutch Solenoid (20) Load Piston (A) Pressure Tap for the Main Relief Valve
(6) Number 4 Clutch Solenoid (21) Load Piston Orifice (B) Pressure Tap for the Priority Valve
(7) Flow Control Orifice (22) Selector Spool (Second Speed) (C) Pressure Tap for Lockup Clutch
(8) Modulating Valve for the Lockup Clutch (23) Power Train Oil Filter for the High (D) Torque Converter Inlet Pressure Tap P3
(9) Modulating Valve for the Impeller Clutch Pressure Circuit (E) Speed Clutch Pressure Tap P1
(10) Slug (24) Power Train Oil Filter for the Low (F) Pressure Tap for Impeller Clutch
(11) Converter Inlet Ratio Valve Pressure Circuit (G) Direction Clutch Pressure Tap P2
(12) Slug (25) Torque Converter Bypass Orifice (H) Pump Pressure Tap
(13) Modulating Relief Valve (26) Power Train Oil Pump (I) Torque Converter Outlet Pressure Tap
(14) Direction Selection Spool (27) Torque Converter Outlet Relief Valve (J) Transmission Lubrication Pressure Tap
(15) Torque Converter (28) Oil Cooler
(16) Lockup Clutch (29) Magnetic Screen
NOTICE
Sudden movement of the machine or release of oil Care must be taken to ensure that fluids are contained
under pressure can cause injury to persons on or during performance of inspection, maintenance, test-
near the machine. ing, adjusting and repair of the product. Be prepared to
To prevent possible injury, perform the procedure ing any compartment or disassembling any compo-
that follows before testing and adjusting the pow- nent containing fluids.
er train.
products.
Personal injury can result from hydraulic oil pres-
sure and hot oil. Dispose of all fluids according to local regulations and
mandates.
ous injury can be caused if this pressure is not re- Operational Checks
leased before any service is done on the hydraulic
system. Note: Operate the machine in each direction and
in all speeds. Note the noises that are not normal
Make sure all of the attachments have been low- and find the sources of the noises. If the machine is
ered, oil is cool before removing any components not operating correctly, refer to the “Troubleshooting
or lines. Remove the oil filler cap only when the en- Problem List” below.
to touch with your bare hand. Troubleshooting Problem List
• Torque converter pressure is high.
• Torque converter pressure is low.
leak, can penetrate body tissue, causing serious • The torque converter overheats.
your skin, it must be treated immediately by a doc- • The torque converter does not respond correctly
tor familiar with this type of injury. for the left service brake pedal.
Always use a board or cardboard when checking • The lockup clutch does not engage.
for a leak.
• The impeller clutch does not engage.
Troubleshooting
Note: Refer to the schematic that is shown in
illustration 1 in order to identify components that are
referenced with a number in the section that follows.
11
Power Train
Use the built-in electrical diagnostics that are a. The oil level is low.
performed with the Vital Information Management
System (VIMS) and with the power train electronic b. There is a restriction in the oil flow circuit or a
control module (ECM) in order to determine the dirty oil strainer.
service codes for the power train ECM.
c. Oil pump failure.
Note: This machine is equipped with a power train
ECM. The power train ECM has built-in diagnostics d. Air leaks on the inlet side of the pump.
that detect faults in the electronic system of the
power train. e. Leakage inside the transmission (worn seals
around the clutch piston)
Reference: For additional information on the
operation of the power train electronic control f. Modulating relief valve (13) is stuck open.
module (ECM) and troubleshooting the power train
ECM, refer to the Service Manual module Systems Problem: The torque converter overheats.
Operation, Testing and Adjusting, RENR2522,
“Power Train Electronic Control System” for Probable causes:
diagnostic procedures for the power train electronic
control. 1. The machine is being used for the wrong
application. There is too much torque converter
Reference: For additional information on slip, which is caused by too much load.
troubleshooting the power train electronic control
module (ECM), refer to the Service Manual, 2. Incorrect transmission gear is being used for the
SENR6059, “Vital Information Management System load that is on the machine. Shift to a lower gear.
(VIMS)” for VIMS diagnostic procedures.
3. The oil level in the transfer gear case is
incorrectly high or low.
Probable Causes of Problems in
the Torque Converter 4. The coolant level in the engine radiator is low.
Problem: Torque converter pressure is high. 5. The oil cooler or oil lines are restricted.
Probable causes: 6. Oil flow through the torque converter is too low.
This may be caused by any of the following
1. There is a restriction inside the torque converter. conditions:
2. Adjustment for torque converter outlet relief valve a. The torque converter inlet ratio valve (11) is
(27) is not correct. bypassing too much oil flow.
3. There is a restriction in an oil passage or in the b. Pump flow or oil pressure is low. Refer to the
oil cooler. Problem: Torque converter pressure is low.
4. Converter inlet ratio valve (11) is stuck in the c. Internal seal leakage inside the torque
closed position. converter is too high.
5. Power train oil is too cold. 7. The transmission oil temperature gauge is faulty.
Problem: Torque converter pressure is low. 8. The torque converter stator clutch has failed.
Probable causes: Problem: The torque converter does not respond

correctly to the left service brake pedal.
1. Converter inlet ratio valve (11) is stuck in the
open position. Probable causes:
2. Adjustment of torque converter outlet relief valve 1. The torque converter is in the mode for reduced
(27) is not correct. rimpull. This changes the response of the left
service brake pedal.
3. The valve spool in torque converter outlet relief
valve (27) does not move. 2. The left service brake pedal is out of calibration.
4. Pump flow or oil pressure is low. This may be 3. The sensor for the left service brake pedal is
caused by any of the following conditions: faulty.
12
Power Train
4. The impeller clutch solenoid or the modulating

valve for the impeller clutch are faulty.
5. There is a problem in the electrical circuit.
Problem: The lockup clutch does not engage.
Probable causes:
1. The on/off switch for the lockup clutch is not in

the ON position.
2. The on/off switch for the lockup clutch is faulty.
3. The lockup clutch solenoid or the modulating

valve for the lockup clutch is faulty.
4. The torque converter output speed sensor is

malfunctioning.
6. There is excessive leakage in the lockup clutch.
7. The magnetic screens are plugged. The oil flow

to the lockup clutch is reduced.
8. The lockup clutch is damaged.
9. The power train oil pump is damaged.
Problem: The impeller clutch does not engage.
Probable causes:
1. The impeller clutch solenoid or the modulating

valve for the impeller clutch are faulty.
3. There is excessive leakage in the impeller clutch.
4. The impeller clutch is damaged.
5. The magnetic screens are plugged. The oil flow

to the lockup clutch is reduced.
6. The power train oil pump is damaged.
i01524598
Transmission Troubleshooting
SMCS Code: 3030-035
13
Power Train
g00790914
Illustration 2
Transmission Hydraulic Schematic
14
Power Train
(1) Number 2 Clutch Solenoid (16) Lockup Clutch (28) Power Train Oil Cooler
(2) Number 3 Clutch Solenoid (17) Impeller Clutch (29) Magnetic Screen
(3) Priority Valve (18) Selector Spool (First Speed and Third (30) Lubrication Passage for Transmission
(4) Number 1 Clutch Solenoid Speed) (31) Reservoir
(7) Flow Control Orifice (21) Load Piston Orifice (B) Pressure Tap for the Priority Valve
(8) Modulating Valve for the Lockup Clutch (22) Selector Spool (Second Speed) (C) Pressure Tap for Lockup Clutch
(9) Modulating Valve for the Impeller Clutch (23) Power Train Oil Filter for the High (D) Torque Converter Inlet Pressure Tap P3
(10) Slug Pressure Circuit (E) Speed Clutch Pressure Tap P1
(11) Converter Inlet Ratio Valve (24) Power Train Oil Filter for the Low (F) Pressure Tap for Impeller Clutch
(12) Slug Pressure Circuit (G) Direction Clutch Pressure Tap P2
(13) Modulating Relief Valve (25) Torque Converter Bypass Orifice (H) Pump Pressure Tap
(14) Direction Selection Spool (26) Power Train Oil Pump (I) Torque Converter Outlet Pressure Tap
(15) Torque Converter (27) Torque Converter Outlet Relief Valve (J) Transmission Lubrication Pressure Tap
NOTICE
Personal injury or death can result from sudden Care must be taken to ensure that fluids are contained
machine movement. during performance of inspection, maintenance, test-
Sudden movement of the machine can cause in- collect the fluid with suitable containers before open-
jury to persons on or near the machine. ing any compartment or disassembling any compo-
nent containing fluids.
To prevent injury or death, make sure that the area
around the machine is clear of personnel and ob- Refer to Special Publication, NENG2500, “Caterpillar
structions before operating the machine. Tools and Shop Products Guide” for tools and supplies
products.
Dispose of all fluids according to local regulations and

Personal injury can result from hydraulic oil pres- mandates.
sure and hot oil.
Hydraulic oil pressure can remain in the hydraulic Operational Checks

ous injury can be caused if this pressure is not re- Note: Operate the machine in each direction and
leased before any service is done on the hydraulic in all speeds. Note the noises that are not normal
system. and find the sources of the noises. If the machine is
not operating correctly, refer to the “Troubleshooting
Make sure all of the attachments have been low- Problem List” below.
or lines. Remove the oil filler cap only when the en- Troubleshooting Problem List
to touch with your bare hand. • The transmission does not operate in any speed
or the transmission slips in all speeds.
• The transmission overheats.

Escaping fluid under pressure, even a pinhole size • Pump noise that is not heard normally.
injury, and possible death. If fluid is injected into • Noise in the transmission that is not normal
tor familiar with this type of injury. • The transmission operates in FORWARD only.
Always use a board or cardboard when checking • The transmission operates in REVERSE only.
for a leak.
• The transmission does not operate in FIRST
SPEED FORWARD or in FIRST SPEED REVERSE.
• The transmission does not operate in SECOND

SPEED FORWARD or in SECOND SPEED
REVERSE.
15
Power Train
• The transmission does not operate in THIRD Check for any service codes that may have been
SPEED FORWARD or in THIRD SPEED REVERSE. generated before troubleshooting a problem. Use
the built-in electrical diagnostics that are performed
• Pressure is low at speed clutch pressure tap P1 with the Vital Information Management System
and at direction clutch pressure tap P2 when the (VIMS) and with the power train electronic control
machine is operated in all directions and in all module (ECM) in order to determine the service
speeds. codes for the power train ECM.
• Pressure is low at direction clutch pressure tap Note: This machine is equipped with a power train
P2 when the machine is operated in REVERSE electronic control. The power train electronic control
speeds. has built-in diagnostics in order to detect faults in
the electronic system for the power train.
• Pressure is low at direction clutch pressure tap
P2 when the machine is operated in FORWARD Reference: For additional information on the
speeds. operation and troubleshooting of the power
train ECM, refer to the Service Manual module
• Pressure is high at speed clutch pressure tap for Systems Operation, Testing and Adjusting,
P1 and at direction clutch pressure tap P2 when RENR2522, “Power Train Electronic Control System”.
the machine is operated in all directions and in
all speeds. Reference: For additional information on
troubleshooting the power train electronic control
• The pressure differential between P1 and P2 is module (ECM), refer to the Service Manual,
not correct. SENR6059, “Vital Information Management System
• Clutch engagement is sudden. (This causes jerky
shifting.) Probable Causes of Transmission
• Clutch engagement is slow. (This causes slow Problems
shifting in all gears.)
Problem: The transmission does not operate in
• Clutch engagement is slow in all FORWARD any speed or the transmission slips in all speeds.
gears, in all REVERSE gears, or in any one gear
speed (FORWARD and REVERSE). Probable causes:
• The machine does not move and engine speed 1. The fuse for the power train control is missing
lugs when the transmission is engaged. or broken.
• The engine is running and the parking brake 2. There is a problem in the electrical circuit.
is engaged. However, the action alarm does
not sound when the transmission is put into 3. Oil pressure is low. This may be caused by any
the FORWARD direction or into the REVERSE of the following conditions:
direction.
a. The oil level is low.
• The backup alarm does not sound when the
transmission is put in REVERSE. b. There is a dirty oil strainer or a restriction in
the oil flow circuit.
• Stall speed is low.
c. Oil pump failure.
• Stall speed is high when the machine is operated
in both directions. d. Air leaks on the inlet side of the pump.
• Stall speed is high when the machine is operated e. There is leakage inside the transmission (worn
in one direction or in one speed. seals around the clutch piston).
f. Modulating relief valve (13) is stuck open.

Troubleshooting
4. There is a torque converter failure.
Note: In the following section, when components are
referenced with a number, refer to the schematic 5. There is a mechanical failure in the transmission.
in illustration 2.
6. Clutch discs and clutch plates are excessively
worn.
16
Power Train
7. The torque converter impeller clutch is not 2. A constant loud noise indicates pump failure.
engaged or the impeller clutch is slipping.
3. There is air at the inlet side of the pump.
Problem: The transmission overheats.
Problem: Noise in the transmission that is not
Probable causes: normal
1. Coolant level in the radiator is low. Probable causes:
2. The machine is being used for the wrong 1. Transmission components are worn or damaged.
application. There is too much torque converter
slip, which is caused by too much load. a. Gears are damaged.
3. Incorrect transmission gear is being used for the b. The teeth of the clutch plates and/or clutch
load that is on the machine. Shift to a lower gear. discs are worn.
4. The temperature gauge is faulty. c. The clutch plates are slipping or noise from
the clutch discs.
5. The oil level is incorrectly high or low.
d. There are other transmission components that
6. The oil cooler or oil lines are restricted. are worn or damaged.
7. The clutch slips too much. This may be caused Problem: The transmission operates in
by any of the following conditions: FORWARD only.
a. Low oil pressure. Refer to the Problem: The Probable causes:

transmission does not operate in any speed
or the transmission slips in all speeds. 1. Number 1 REVERSE clutch solenoid (4) is
inoperative.
b. A clutch is damaged.
8. Oil flow is low. This may be caused by pump
wear or by leakage in the transmission hydraulic 3. The REVERSE clutch is not engaged or the
system. REVERSE clutch slips. This may be caused by
any of the following conditions:
9. There is air in the oil. This may be caused by air
leaks on the intake side of the pump. a. Low oil pressure due to leaking piston seals.
10. The magnetic screen for the pump inlet is b. The clutch discs and clutch plates have too
plugged. much wear.
11. The converter inlet ratio valve (11) is stuck c. Clutch components are broken.
open. This causes low oil flow through the torque
converter. 4. Selector spool (14) is stuck.
12. The clutch or clutches are not fully released. Problem: The transmission operates in REVERSE
(This is called clutch drag.) This may be caused only.
by any of the following conditions:
Probable causes:
a. There are warped plates or warped discs.
1. Number 2 FORWARD clutch solenoid (1) is
b. A return spring is broken or weak. inoperative.
Problem: Pump noise that is not heard normally. 2. There is a problem in the electrical circuit.
Probable causes: 3. The FORWARD clutch is not engaged or the

FORWARD clutch slips. This may be caused by
1. A loud noise at short intervals indicates that any of the following conditions:
foreign material is in the transmission hydraulic
system. a. Low oil pressure due to leaking piston seals.
17
Power Train
b. The clutch discs and clutch plates have too 2. There is a problem in the electrical circuit.
much wear.
3. The THIRD SPEED clutch is not engaged or the
c. Clutch components are broken. THIRD SPEED clutch slips. This may be caused
by any of the following conditions:
4. Selector spool (14) is stuck.
a. Low oil pressure due to leaking piston seals.
Problem: The transmission does not operate in
FIRST SPEED FORWARD or in FIRST SPEED b. The clutch discs and clutch plates have too
REVERSE. much wear.
Probable causes: c. Clutch components are broken.
1. Number 5 speed clutch solenoid FIRST SPEED 4. Selector spool (18) is stuck.
(5) is inoperative.
Problem: Pressure is low at speed clutch
2. There is a problem in the electrical circuit. pressure tap P1 and at direction clutch pressure
tap P2 when the machine is operated in all
3. The FIRST SPEED clutch is not engaged or the directions and in all speeds.
FIRST SPEED clutch slips. This may be caused
by any of the following conditions: Probable causes:
a. Low oil pressure due to leaking piston seals. 1. Modulating relief valve (13) is stuck.
b. The clutch discs and clutch plates have too a. The modulating relief valve is not adjusted
much wear. properly.
c. Clutch components are broken. 2. Low oil pressure. Refer to the Problem: The
transmission does not operate in any speed or
4. Selector spool (18) is stuck. the transmission slips in all speeds.
Problem: The transmission does not operate 3. Springs of load piston (20) are weak or damaged.
in SECOND SPEED FORWARD or in SECOND Springs or spacers are missing.
SPEED REVERSE.
4. Priority valve (3) is stuck open to the torque
Probable causes: converter circuit.
1. Number 4 speed clutch solenoid SECOND Problem: Pressure is low at direction clutch
SPEED FORWARD (6) is inoperative. pressure tap P2 when the machine is operated in
REVERSE speeds.
Probable causes:
3. The SECOND SPEED clutch is not engaged or
the SECOND SPEED clutch slips. This may be There is too much leakage in the piston seals of
caused by any of the following conditions: the REVERSE clutch.
a. Low oil pressure due to leaking piston seals. Problem: Pressure is low at direction clutch
pressure tap P2 when the machine is operated
b. The clutch discs and clutch plates have too in FORWARD speeds.
much wear.
Probable causes:
c. Clutch components are broken.
There is too much leakage in the piston seals of the
4. Selector spool (22) is stuck. FORWARD clutch.
Problem: The transmission does not operate in Problem: Pressure is high at speed clutch
THIRD SPEED FORWARD or in THIRD SPEED pressure tap P1 and at direction clutch pressure
REVERSE. tap P2 when the machine is operated in all
directions and in all speeds.
Probable causes:
Probable causes:
1. Number 3 speed clutch solenoid THIRD SPEED
(2) is inoperative. 1. Modulating relief valve (13) is sticking.
18
Power Train
2. Load piston (20) is stuck. Probable causes:
3. The wrong load piston springs or too many Clutch pressure is low because of leaking seals on
spacers are being used. the piston for the affected gear.
4. Slug (12) is worn. The bore for the modulating Problem: The machine does not move and the
relief valve (13) is worn. engine lugs when the transmission is engaged.
Problem: The pressure differential between P1 Probable causes:

and P2 is not correct.
1. Service brakes are locked up.
Probable causes:
2. The parking brake is not released. Also, the
Pressure differential valve (19) is not operating parking brake may be locked up.
correctly because of a spring that is weak or
damaged. Also, the wrong spring may be installed. 3. There is a mechanical failure in a differential
(front differential or rear differential).
Problem: Clutch engagement is sudden. (This
causes jerky shifting.) 4. There is a mechanical failure in a final drive.
Probable causes: 5. Gears in the transmission do not turn because

there is a mechanical failure in the transmission
1. Pressure differential valve (19) is not operating or too many clutches are engaged.
correctly because of a spring that is weak
or damaged. Also, the wrong spring may be Problem: The engine is running and the parking
installed. brake is engaged. However, the action alarm
does not sound when the transmission is put into
2. Load piston (20) is stuck. the FORWARD direction or into the REVERSE
direction.
3. The wrong load piston springs are being used or
the load piston springs are damaged. Probable causes:
4. The screen orifice that is used for the load piston There is a problem in the electrical circuit.
was not installed.
Problem: The backup alarm does not sound when
5. The impeller clutch is not cycling properly during the transmission is put in REVERSE.
the shift.
Probable causes:
Problem: Clutch engagement is slow. (This
causes slow shifting in all gears.) 1. The backup alarm fuse has failed.
Probable causes: 2. The backup alarm has failed.
1. The screen orifice for the load piston is dirty or 3. There is a problem in the electrical circuit.
plugged.
Problem: Stall speed is low.
2. Oil pressure is low. Refer to the Problem: The
transmission does not operate in any speed or Probable causes:
the transmission slips in all speeds.
1. Engine performance is not correct.
3. The wrong load piston springs are being used or
the load piston springs are damaged. a. The quality of the diesel fuel is poor.
4. Modulating relief valve (13) is stuck. b. Engine air filters are plugged.
5. The impeller clutch solenoid valve (9) has c. Engine fuel lines are restricted.
malfunctioned.
2. The oil is cold.
Problem: Clutch engagement is slow in all
FORWARD gears, in all REVERSE gears, or in any 3. The torque converter stator clutch has failed.
one gear speed (FORWARD and REVERSE).
19
Power Train
Problem: Stall speed is high when the machine is

operated in both directions.
Probable causes:
1. Oil level is low.
2. There is air in the oil.
3. Direction clutches are slipping.
for a leak.
4. There is a failure in the torque converter.
NOTICE
5. The torque converter impeller clutch is slipping. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
Problem: Stall speed is high when the machine is ing, adjusting and repair of the product. Be prepared to
operated in one direction or in one speed. collect the fluid with suitable containers before open-
Probable causes: nent containing fluids.
1. There is a leak in the clutch circuit. Refer to Special Publication, NENG2500, “Caterpillar
2. There is a failure in the direction clutch or in the suitable to collect and contain fluids on Caterpillar
speed clutch that has high stall speed. products.
i01400636
mandates.
Differential and Final Drive
Troubleshooting Operational Checks
SMCS Code: 3258-035; 4051-035 Note: Operate the machine in each direction and
in all speeds. Note the noises that are not normal
and find the sources of the noises. If the machine is
not operating correctly, refer to the “Troubleshooting
Personal injury or death can result from sudden Problem List” below.
machine movement.
Troubleshooting Problem List
Sudden movement of the machine can cause in-
jury to persons on or near the machine. • There is constant noise in the differential.
To prevent injury or death, make sure that the area • Noise occurs in the differential at different
around the machine is clear of personnel and ob- intervals.
structions before operating the machine.
• Noise only occurs during turns.
• Lubricant is leaking.
Personal injury can result from hydraulic oil pres- • The drive wheels do not turn but the universal
sure and hot oil. joint turns.
system after the engine has been stopped. Seri- Troubleshooting
ous injury can be caused if this pressure is not re-
leased before any service is done on the hydraulic Solve any active service codes for the power
system. train electronic control. Use the built-in electrical
diagnostics that are performed with the Vital
Make sure all of the attachments have been low- Information Management System (VIMS) and with
ered, oil is cool before removing any components the electronic control module.
20
Power Train
Note: This machine is equipped with a power train 1. Differential pinion gears are too tight on the
electronic control. The power train electronic control pinion shaft.
has built-in diagnostics that detect faults in the
electronic system of the power train. 2. Side gears are too tight in the differential case.
Reference: For additional information on the 3. Differential pinion gears or side gears are faulty.
operation and troubleshooting of the power
train ECM, refer to the Service Manual module 4. Thrust washers are damaged or worn.
for Systems Operation, Testing and Adjusting,
RENR2522, “Power Train Electronic Control System”. 5. There is too much backlash between the side
gears and the pinion gears.
Reference: For additional information on
troubleshooting the power train electronic control Problem: Lubricant is leaking.
module (ECM), refer to the Service Manual,
SENR6059, “Vital Information Management System Probable causes:
1. Loss of lubricant through the axle shafts can be
caused by any of the following conditions:
Probable Causes of Problems in
the Differential and Drive Axle a. Lubricant is above the proper level.
Problem: There is constant noise in the b. The wrong type of lubricant is being used.
differential.
c. There is a restriction in the axle housing
Probable causes: breather.
1. The level of lubricant is incorrectly high or low. d. There is an oil seal that is worn or installed
incorrectly.
2. The wrong type of lubricant is being used.
2. Loss of lubricant at the pinion shaft can be
3. Wheel bearings are damaged or improperly caused by the following conditions:
adjusted.
a. Lubricant is above the proper level.
4. The bevel gear and the pinion do not have
correct tooth contact. b. The wrong type of lubricant is being used.
5. The bevel gear and the pinion are damaged or c. There is a restriction in the axle housing
worn. breather.
6. There is too much pinion to bevel gear backlash d. An oil seal on the pinion shaft is worn or
or too little pinion to bevel gear backlash. installed incorrectly.
7. Pinion bearings are loose or worn. e. A universal joint flange is loose on the pinion
shaft.
8. Side bearings are loose or worn.
Problem: The drive wheels do not turn but the
Problem: Noise occurs in the differential at universal joint turns.
different intervals.
Probable causes:
Probable causes:
1. An axle shaft is broken.
1. Bevel gear does not run evenly because the
bolts on the bevel gear are not tight or the bevel 2. Bevel gear teeth are damaged.
gear is warped.
3. The side gear or the differential pinion is broken.
2. Differential bearings are loose or broken.
4. The differential pinion shaft is broken.
Problem: Noise only occurs during turns.
Probable causes:
21
Power Train

i01401660
Torque Converter Inlet

Pressure - Test
SMCS Code: 3101-081-PX
g00738516
Illustration 3
Hydraulic Schematic for the Torque Converter
(1) Priority Valve (9) Impeller Clutch (B) Pressure Tap for the Priority Valve
(2) Modulating Valve for the Lockup Clutch (10) Power Train Oil Pump (C) Pressure Tap for Lockup Clutch
(3) Modulating Valve for the Impeller Clutch (11) Torque Converter Outlet Relief Valve (D) Torque Converter Inlet Pressure Tap P3
(4) Transmission Hydraulic Controls (12) Torque Converter Bypass Orifice (E) Pressure Tap for Oil Pump
(5) Power Train Oil Filter for the High (13) Magnetic Screen (F) Pressure Tap for Impeller Clutch
Pressure Circuit (14) Oil Cooler (G) Lubrication Pressure Tap
(6) Power Train Oil Filter for the Low (15) Reservoir in Output Transfer Gear Case (H) Torque Converter Outlet Pressure Tap
Pressure Circuit (16) Outlet Line from Oil Cooler to Planetary
(7) Torque Converter Lubrication
(8) Lockup Clutch (A) Pressure Tap for the Main Relief Valve
22
Power Train
5. Place blocks in front of the wheels and behind

the wheels.
7. Allow only authorized personnel on the machine.

Keep unauthorized personnel off the machine
and in clear sight of the operator.
NOTICE
Do not connect or disconnect hose fittings to or from
the quick disconnect nipples when there is pressure in
the system. This will prevent damage to the seals that
are in the fitting.
g00446991
Illustration 4
(D) Torque Converter Inlet Pressure Tap P3. Table 1
Required Tools
Part
Description Quantity
Number
Personal injury or death can result from sudden
machine movement. 1U-5481 Pressure Gauge Group 1
1U-5482 Pressure Adapter Group 1
jury to persons on or near the machine.
1. Install a hose and a 1400 kPa (200 psi) pressure
Prevent possible injury by performing the proce- gauge on pressure tap (D).
dure that follows before working on the machine.
2. Start the engine and run the engine at high idle.
NOTICE 3. The pressure on the gauge must not exceed

Care must be taken to ensure that fluids are contained 930 kPa (135 psi) with cold oil.
ing, adjusting and repair of the product. Be prepared to Note: There is no adjustment for this pressure. This
collect the fluid with suitable containers before open- pressure depends on P1 oil pressure. The ratio
ing any compartment or disassembling any compo- valve in the selector and pressure control valve
nent containing fluids. controls the P1 pressure.

i01644224
products.
Torque Converter Outlet
Pressure - Test
mandates. SMCS Code: 3101-081-PX

location that is away from operating machines
and away from personnel.

Keep all other personnel away from the machine
or in the operator’s sight.

switch to the NEUTRAL position.
3. Lower the work tool to the ground.

23
Power Train
g00738516
Illustration 5
(1) Priority Valve (9) Impeller Clutch (A) Pressure Tap for the Main Relief Valve
(2) Modulating Valve for the Lockup Clutch (10) Power Train Oil Pump P1
(3) Modulating Valve for the Impeller Clutch (11) Torque Converter Outlet Relief Valve (B) Pressure Tap for the Priority Valve
(4) Transmission Hydraulic Controls (12) Torque Converter Bypass Orifice (C) Pressure Tap for Lockup Clutch
(5) Power Train Oil Filter for the High (13) Magnetic Screen (D) Torque Converter Inlet Pressure Tap P3
Pressure Circuit (14) Oil Cooler (E) Pressure Tap for Oil Pump
(6) Power Train Oil Filter for the Low (15) Reservoir in Output Transfer Gear Case (F) Pressure Tap for Impeller Clutch
Pressure Circuit (16) Outlet Line from Oil Cooler to Planetary (G) Lubrication Pressure Tap
(7) Torque Converter Lubrication (H) Torque Converter Outlet Pressure Tap
(8) Lockup Clutch
24
Power Train

the wheels.

NOTICE
are in the fitting.
g00447043
Illustration 6
(H) Pressure Tap for the Torque Converter Outlet Oil. (The
pressure tap is located on the torque converter case on the right
side of the machine.)

machine movement.

Prevent possible injury by performing the proce-

dure that follows before working on the machine. g00447603
Illustration 7
(11) Torque Converter Outlet Relief Valve. (17) Spacers.
NOTICE
Care must be taken to ensure that fluids are contained Table 2
during performance of inspection, maintenance, test- Required Tools
collect the fluid with suitable containers before open- Part
ing any compartment or disassembling any compo- Number
nent containing fluids. 1U-5481 Pressure Gauge Group 1
Refer to Special Publication, NENG2500, “Caterpillar 1U-5482 Pressure Adapter Group 1

products.
Dispose of all fluids according to local regulations and The input drive shaft rotates between the torque
mandates. converter and the transmission whenever the en-
gine is running. Contact with the rotating shaft can
result in personal injury or death.
location that is away from operating machines The rotating shaft is located under the door as-
and away from personnel. semblies that are behind the machine cab. Do not
allow personnel into the area behind the cab when
Note: Permit only one operator on the machine. the machine is running.
2. Move the STIC transmission direction control gauge on pressure tap (H).
3. Lower the work tool to the ground. switch to the NEUTRAL position. Engage the
parking brake. Start the engine.
25
Power Train
3. Display the engine rpm on the display of the Vital Table 3

Information Management System (VIMS). Pressure Change for One Spacer(1)
Reference: For more information on the Vital Pressure
Description Thickness Part
Information Management System (VIMS), refer to Change
the Service Manual, SENR6059, “Vital Information
Management System (VIMS)”. 5M-9623 0.91 mm 18.2 kPa Output
Spacer (.036 inch) (2.64 psi) Relief
Note: Make sure that the engine can operate at the 5M-9624 0.25 mm 5.0 kPa Valve
correct high idle rpm. The correct high idle rpm is Spacer (.010 inch) (.73 psi) (11)
1700 ± 50 rpm. Make sure that the power train oil is (1) Before an adjustment is made to outlet relief valve (11), make
at normal operating temperature. sure that the valve springs are not weak or broken.
4. Apply the service brakes with the right service Reference: For more information on adding
brake pedal. Release the parking brake. or removing spacers, refer to the Service
Manual module Power Train Disassembly and
5. Place the transmission in THIRD SPEED. Assembly, “Relief Valve (Torque Converter
Outlet) - Assemble” for the machine that is being
6. Move the STIC transmission direction control serviced.
switch to the REVERSE position.
7. Slowly increase the engine rpm to full throttle. i01403228

The machine will try to move.
Torque Converter Impeller
Note: If the service brakes do not keep the machine Clutch Pressure - Test
from moving, put the machine against a solid object
that will not move. SMCS Code: 3102-081-PX
Note: Do not keep the torque converter in a stall

condition for more than 30 seconds. Damage could
occur in the power train if the torque converter is
kept in a stall condition too long.
8. The engine rpm must be 1545 ± 65 rpm with the

torque converter in stall condition.
9. The pressure on the gauge must be

345 to 550 kPa (50 to 80 psi).
10. Reduce the engine speed to low idle.

13. Increase the engine speed to 1300 rpm in

order to lower the power train oil to the normal
operating temperature.
14. After the power train oil has returned to the

normal operating temperature, stop the engine
and remove the test equipment.
15. If the torque converter outlet pressure is not

correct, adjust the pressure by adding or
removing spacers (17). Refer to Table 3 for more
information on changing spacers.
26
Power Train
g00738516
Illustration 8
27
Power Train

machine movement.


NOTICE
Illustration 9 g00738898 during performance of inspection, maintenance, test-
(C) Pressure Tap for the Lockup Clutch. (F) Pressure Tap for the
Impeller Clutch. (The pressure taps are located on the torque
converter case on the left side of the machine.) ing any compartment or disassembling any compo-

products.

mandates.

g00446991 Note: Permit only one operator on the machine.

Illustration 10 Keep all other personnel away from the machine
(D) Torque Converter Inlet Pressure Tap. (The pressure tap is or in the operator’s sight.
located on the top front of the transmission.)

the wheels.

g00447043 and in clear sight of the operator.
Illustration 11
(H) Pressure Tap for the Torque Converter Outlet Oil. (The Note: All tests and all adjustments must be made
while the transmission oil is at normal operating
temperature.
NOTICE
are in the fitting.
28
Power Train
g00447603
Illustration 12
(11) Torque converter outlet relief valve. (17) Spacers.
Table 4
Torque Converter Pressure
Pressure
Pressure Pressure at High Idle Adjustment
Tap
Lockup Stabilized pressure with an activated solenoid is 2205 ± 345 kPa (320 ± 50 psi). -
(C)
Clutch Pressure is less than 205 kPa (30 psi) when the solenoid is not activated.
Torque
Converter (D) Maximum pressure with cold oil is 930 kPa (135 psi). -
Inlet
Impeller Maximum pressure is 1965 ± 100 kPa (285 ± 15 psi). -

(F)
Clutch Minimum pressure is 400 ± 100 kPa (58 ± 15 psi).
Maximum pressure is 550 kPa (80 psi).

Torque Add spacers
Minimum pressure is 345 kPa (50 psi).
Converter (H) (17) or remove
(These pressures are for a machine in third speed, with activated brakes, with
Outlet spacers (17).
installed axle shafts, and with the torque converter in a stall condition.)
Table 5 Maximum and Minimum Clutch

Required Tools Pressure
Part
Number
1U-5481 Pressure Gauge Group 1
The input drive shaft rotates between the torque
1U-5482 Pressure Adapter Group 1 converter and the transmission whenever the en-
The rotating shaft is located under the door as-

semblies that are behind the machine cab. Do not
the machine is running.
29
Power Train
i01853874
Torque Converter Lockup

machine movement. Clutch Pressure - Test
Sudden movement of the machine can cause in- SMCS Code: 3102-081-PX

around the machine is clear of personnel and ob-
structions before moving the machine to perform
the test that follows.
Note: Make sure that the modulating valve for

the torque converter impeller clutch is calibrated
correctly before performing pressure tests. The test
values can be affected if the modulating valve is
not calibrated correctly.
Reference: For additional information on the

calibration procedure for the modulating valve for
the torque converter impeller clutch, refer to the
Service Manual module for Systems Operation,
Testing and Adjusting, RENR2522, “Power Train
Electronic Control System”.
Note: The reduced rimpull setting for the minimum

impeller clutch pressure can be modified in the
field. The power train electronic control module
(ECM) must be programmed to the default reduced
rimpull setting before a pressure test of the impeller
clutch can be performed. The default setting for
the left service brake pedal is approximately 30
percent rimpull.
Reference: For more information on programming

the set points for reduced rimpull, refer to the
Service Manual module for Systems Operation,
Testing and Adjusting, RENR2522, “Power Train
Electronic Control System”.

gauge on pressure tap (F).

switch to the NEUTRAL position. Start the engine.
4. Move the reduced or maximum rimpull switch to

the MAXIMUM position.
5. Run the engine at high idle and observe the

pressure reading on the gauge. The maximum
pressure equals 1965 ± 100 kPa (285 ± 15 psi).
6. With the engine at high idle, completely depress

the left service brake pedal and observe the
pressure reading on the gauge. The minimum
impeller clutch pressure equals 400 ± 100 kPa
(58 ± 15 psi).
30
Power Train
g00738516
Illustration 13
31
Power Train

machine movement.


NOTICE
Illustration 14 g00738898 during performance of inspection, maintenance, test-
Impeller Clutch. (The pressure taps are located on the torque
converter case on the left side of the machine.) ing any compartment or disassembling any compo-

products.

mandates.

g00446991 Note: Permit only one operator on the machine.

Illustration 15 Keep all other personnel away from the machine
(D) Torque Converter Inlet Pressure Tap. (The pressure tap is or in the operator’s sight.
located on the top front of the transmission.)

the wheels.

g00447043 and in clear sight of the operator.
Illustration 16
(H) Pressure Tap for the Torque Converter Outlet Oil. (The Note: All tests and all adjustments must be made
temperature.
NOTICE
are in the fitting.
32
Power Train
g00447603
Illustration 17
(11) Torque Converter Outlet Relief Valve. (17) Spacers.
Table 6
Torque Converter Pressure
Pressure
Pressure Pressure at High Idle Adjustment
Tap
Lockup Stabilized pressure with an activated solenoid is 2205 ± 345 kPa (320 ± 50 psi). -
(C)
Clutch Pressure is less than 205 kPa (30 psi) when the solenoid is not activated.
Torque
Converter (D) Maximum pressure with cold oil is 930 kPa (135 psi). -
Inlet
Impeller Maximum pressure is 1965 ± 100 kPa (285 ± 15 psi). -

(F)
Clutch Minimum pressure is 400 ± 100 kPa (58 ± 15 psi).
Maximum pressure is 550 kPa (80 psi).

Torque Add spacers
Minimum pressure is 345 kPa (50 psi).
Converter (H) (17) or remove
(These pressures are for a machine in third speed, with activated brakes, with
Outlet spacers (17).
installed axle shafts, and with the torque converter in a stall condition.)
Table 7 Lockup Clutch Disengaged

Pressure Change for One Spacer(1) (Minimum clutch pressure)
Pressure
Description Thickness Part
Change
5M-9623 0.91 mm 18.2 kPa Output

Spacer (.036 inch) (2.64 psi) The input drive shaft rotates between the torque
Relief converter and the transmission whenever the en-
5M-9624 0.25 mm 5.0 kPa Valve
(11)
Spacer (.010 inch) (.73 psi) result in personal injury or death.
(1) Before an adjustment is made to outlet relief valve (11), make
sure that the valve springs are not weak or broken. The rotating shaft is located under the door as-
Table 8 allow personnel into the area behind the cab when
Required Tools the machine is running.
Part
Number
33
Power Train

gauge on pressure tap (C).
2. Move the lockup clutch switch to the ENABLE
machine movement.
position.
switch to the NEUTRAL position. Start the engine.
5. Apply the service brakes and release the parking
brake.
1. Install a hose and a 4130 kPa (600 psi) pressure 6. Place the transmission in SECOND SPEED.
gauge on pressure tap (C).
2. Move the lockup clutch switch to the DISABLE switch to the FORWARD position.
position.
8. Increase the engine speed to high idle.
9. Operate the machine at maximum speed and
4. Move the STIC transmission direction control observe the pressure reading on the gauge.
switch to the NEUTRAL position. Start the engine. Make sure that the left service brake pedal or the
right service brake pedal are not depressed. If
5. Increase the engine speed to high idle. the left service brake pedal or the right service
brake pedal are depressed the lockup clutch will
6. Observe the pressure gauge. The pressure not engage. The maximum stabilized pressure
reading on the gauge must be 205 kPa (30 psi) must be 2205 ± 345 kPa (320 ± 50 psi).
or less.
i01404594
Lockup Clutch Engaged (Maximum
stabilized pressure) Reduced Rimpull Pressure -
Test
SMCS Code: 3140-081-PX
The input drive shaft rotates between the torque
converter and the transmission whenever the en-


machine movement.


34
Power Train
g00738516
Illustration 18
35
Power Train

the wheels.

Note: All tests and all adjustments must be made

temperature.
NOTICE
Illustration 19 g00738898 Do not connect or disconnect hose fittings to or from
Impeller Clutch. (The pressure taps are located on the torque the system. This will prevent damage to the seals that
converter case on the left side of the machine.) are in the fitting.
Table 9
Required Tools
machine movement. Part
Number
Sudden movement of the machine can cause in- 1U-5481 Pressure Gauge Group 1
NOTICE The input drive shaft rotates between the torque

Care must be taken to ensure that fluids are contained converter and the transmission whenever the en-
during performance of inspection, maintenance, test- gine is running. Contact with the rotating shaft can
ing, adjusting and repair of the product. Be prepared to result in personal injury or death.
ing any compartment or disassembling any compo- The rotating shaft is located under the door as-
nent containing fluids. semblies that are behind the machine cab. Do not
Refer to Special Publication, NENG2500, “Caterpillar the machine is running.
products.
Dispose of all fluids according to local regulations and Personal injury or death can result from sudden
mandates. machine movement.

1. Move the machine to a smooth, horizontal jury to persons on or near the machine.
and away from personnel. To prevent injury or death, make sure that the area
Note: Permit only one operator on the machine. structions before moving the machine to perform
Keep all other personnel away from the machine the test that follows.
2. Move the STIC transmission direction control Note: The default settings for reduced rimpull can
switch to the NEUTRAL position. be changed in the field. The power train electronic
control module (ECM) must be set to the default
3. Lower the work tool to the ground. reduced rimpull settings before a test of the four
reduced rimpull settings can be performed.
36
Power Train
Reference: Refer to the Service Manual module If the engine speed is lower than the normal given
for Systems Operation, Testing and Adjusting, speed or if the engine speed is higher than the
RENR2522, “Power Train Electronic Control System” normal given speed, this indicates that there is
for the procedure for programming the set points a problem in the engine or in the transmission.
for reduced rimpull. The following values are the If testing shows correct engine performance but
default settings for reduced rimpull: 45 percent, 55 the torque converter stall speed is not correct,
percent, 70 percent, and 85 percent. the problem is in the torque converter or in the
transmission.
gauge on pressure tap (F). Reference: To check the performance of the
Caterpillar 3516B Engine, refer to the following
2. Engage the parking brake. service literature: Specifications, RENR2210, “3516B
Engine For Caterpillar Built Machines” and Systems
3. Move the STIC transmission direction control Operation, Testing and Adjusting, RENR2211,
switch to the NEUTRAL position. Start the engine. “3516B Engine For Caterpillar Built Machines”.
4. Move the reduced or maximum rimpull switch to

the REDUCED position. The indicator light for
reduced rimpull must come on.
5. Move the reduced rimpull selection switch to the machine movement.
MINIMUM position (small dot).
6. Increase the engine speed to high idle and jury to persons on or near the machine.
observe the pressure reading on the gauge.
Record the gauge reading. To prevent injury or death, make sure that the area
7. With the engine at high idle, move the reduced structions before operating the machine.
rimpull selection switch to each of the remaining
positions. Record the pressure reading at each The service brakes must be applied when tests
of the switch positions. Refer to Table 10 below are performed. Make sure that the service brakes
for the correct pressures. are fully operational before you perform any tests.
Make sure that the transmission oil is at the normal
Table 10 operating temperature when tests are performed.
Impeller Clutch Pressure
Reduced Rimpull Settings 1. Move the machine to a smooth, horizontal
Setting Pressure
45% 680 kPa (100 psi)
55% 800 kPa (116 psi)
70% 1015 kPa (150 psi) or in the operator’s sight.
85% 1275 kPa (185 psi) 2. Move the STIC transmission direction control
i01644213 3. Lower the work tool to the ground.
Torque Converter Stall - Test 4. Engage the parking brake.
SMCS Code: 3101-081-V8
The torque converter stall test is designed to test the wheels.
the engine, the torque converter, the drive train and
the brake system as a unit. The torque converter 6. Allow only authorized personnel on the machine.
output is stalled while the engine is operated at Keep unauthorized personnel off the machine
full throttle. The speed of the engine at torque and in clear sight of the operator.
converter stall indicates whether the engine and the
transmission are operating correctly under full load. 7. Apply the service brakes and start the engine.
37
Power Train
Note: To ensure that the transmission oil does not

overheat, do not keep the torque converter in a full
stall condition for more than 30 seconds.
8. Place the transmission in THIRD SPEED.
9. Disengage the parking brake.

switch to the FORWARD position.
11. Increase the engine speed to high idle.
12. Allow the engine rpm to stabilize. Then, observe

the engine speed with the Vital Information
Management System (VIMS).
Reference: For additional information on

observing the engine speed with the Vital
Information Management System (VIMS), refer
to the Operation and Maintenance Manual,
SEBU7145, “994D Wheel Loader”, “Parameters
(VIMS Monitoring System)”.
13. The correct stall speed is 1545 ± 65 rpm.
14. After the torque converter is stalled, move the

STIC transmission direction control switch to the
NEUTRAL position. Operate the engine at 900
rpm to 1200 rpm in order to cool the oil.
Stall speeds that are low indicate either incorrect

engine performance or incorrect torque converter
performance. Stall speeds that are high indicate
incorrect transmission performance or incorrect
performance of the torque converter. If you must
repeat the test, keep the transmission in neutral and
wait for two minutes between tests.
Reference: For additional information about the Vital

Information Management System (VIMS), refer to
the Service Manual, SENR6059, “Vital Information
Management System (VIMS)”.
Reference: For additional information about

troubleshooting the transmission and the torque
converter, refer to the Service Manual module
Testing and Adjusting, RENR2506, “994D Wheel
Loader Power Train”.
i01404817
Transmission Pressures - Test

and Adjust
SMCS Code: 3030-025-PX; 3030-081-PX
38
Power Train
g00771976
Illustration 20
Transmission Hydraulic Schematic
39
Power Train
(1) Number 2 Clutch Solenoid (16) Lockup Clutch (28) Power Train Oil Cooler
(2) Number 3 Clutch Solenoid (17) Impeller Clutch (29) Magnetic Screen
(3) Priority Valve (18) Selector Spool (First Speed and Third (30) Lubrication Passage for Transmission
(4) Number 1 Clutch Solenoid Speed) (31) Reservoir
(7) Flow Control Orifice (21) Load Piston Orifice (B) Pressure Tap for the Priority Valve
(8) Modulating Valve for the Lockup Clutch (22) Selector Spool (Second Speed) (C) Pressure Tap for Lockup Clutch
(9) Modulating Valve for the Impeller Clutch (23) Power Train Oil Filter for the High (D) Torque Converter Inlet Pressure Tap P3
(10) Slug Pressure Circuit (E) Speed Clutch Pressure Tap P1
(11) Converter Inlet Ratio Valve (24) Power Train Oil Filter for the Low (F) Pressure Tap for Impeller Clutch
(12) Slug Pressure Circuit (G) Direction Clutch Pressure Tap P2
(13) Modulating Relief Valve (25) Torque Converter Bypass Orifice (H) Pump Pressure Tap
(14) Direction Selection Spool (26) Power Train Oil Pump (I) Torque Converter Outlet Pressure Tap
(15) Torque Converter (27) Torque Converter Outlet Relief Valve (J) Transmission Lubrication Pressure Tap
7. Remove the front axle shafts and the rear axle

shafts except for the stall tests.
machine movement.
Note: All tests and all adjustments must be made
temperature.
NOTICE
Care must be taken to ensure that fluids are contained The input drive shaft rotates between the torque
during performance of inspection, maintenance, test- converter and the transmission whenever the en-
ing, adjusting and repair of the product. Be prepared to gine is running. Contact with the rotating shaft can
collect the fluid with suitable containers before open- result in personal injury or death.
nent containing fluids. The rotating shaft is located under the door as-
Refer to Special Publication, NENG2500, “Caterpillar allow personnel into the area behind the cab when
Tools and Shop Products Guide” for tools and supplies the machine is running.
products.
NOTICE
Dispose of all fluids according to local regulations and Do not connect or disconnect hose fittings to or from
mandates. the quick disconnect nipples when there is pressure in
1. Move the machine to a smooth, horizontal are in the fitting.
and away from personnel. Table 11
Required Tools
Keep all other personnel away from the machine Part
or in the operator’s sight. Number
switch to the NEUTRAL position. 1U-5482 Pressure Adapter Group 1

the wheels.

40
Power Train
Test Procedures
Table 12
Transmission Speed
Engaged Clutches
Selection
Third Speed Forward Number 2 and Number 3
Second Speed Forward Number 2 and Number 4
First Speed Forward Number 2 and Number 5
Neutral Number 3
First Speed Reverse Number 1 and Number 5
Second Speed Reverse Number 1 and Number 4
Third Speed Reverse Number 1 and Number 3
g00740501
Illustration 22
Transmission
(D) Torque Converter Inlet Pressure Tap P3. (E) Speed Clutch
g00740476
Illustration 21 Pressure Tap P1. (G) Direction Clutch Pressure Tap P2. (J)
(D) Torque Converter Inlet Pressure Tap P3. (E) Speed Clutch Transmission Lubrication Pressure Tap.
Pressure Tap P1.
g00453841
Illustration 23
Power Train Oil Filters
“PT OIL FLTR PLGD” will be displayed on the Vital Information
Management System (VIMS) if the filter becomes plugged.
(H) Pressure tap for the power train oil pump. (The pressure tap
is located on the left side of the machine.)
41
Power Train
4. Perform Step 3 for all reverse speeds. The same

pressure levels should be noted in all reverse
speeds.
Test for the Lubrication Oil Pressure

Use the following procedure to check the pressure
of the transmission lubrication oil.
g00740506
Illustration 24
Transmission Selector and Pressure Control Valve g00454785
Illustration 25
The transmission selector and pressure control valve is on the top
of the transmission. The transmission cover is removed. (J) Transmission Lubrication Pressure Tap.
(K) Speed Clutch Pressure Tap P1. (L) Plug for Load Piston LP. The pressure tap is located on the rear of the transmission case
toward the front of the machine.
1. Install the correct hose assembly from 1U-5482
Pressure Adapter Group on the following 1. Install the correct hose assembly from 1U-5482
pressure taps: (E), (G), and (H). Attach the Pressure Adapter Group on pressure tap (J).
opposite end of the hose assembly to the Attach the opposite end of the hose assembly to
0 to 3400 kPa (0 to 580 psi) pressure gauge in the 0 to 400 kPa (0 to 58 psi) pressure gauge in
the 1U-5481 Pressure Gauge Group. the 1U-5481 Pressure Gauge Group.
2. Engage the parking brake. Shift the STIC 2. Start the engine and operate the engine at high
transmission direction control switch to the idle. Observe the pressure gauge. With the oil at
NEUTRAL position. Shift the transmission to first normal operating temperature, the lubrication oil
speed. Start the engine and operate the engine pressure must be within values that are found
at low idle. in Table 13.
3. Depress the right service brake pedal and

hold the right service brake pedal. Release the
parking brake. Watch the pressure gauges. Shift
the STIC transmission direction control switch
from the NEUTRAL position to the FORWARD
position. Increase the engine speed to high
idle. Make sure that the transmission oil is at
normal operating temperature. The needle on the
pressure gauge for the Number 2 clutch should
rise. The needle on the pressure gauge for
the Number 5 clutch should rise. The pressure
readings must be within the values that are found
in Table 13.
With the transmission in the FORWARD position,

shift through the remaining forward speeds and
return to the FIRST SPEED position. The pressure
reading for each clutch that is energized must be
within the values that are found in Table 13. This
checks the pressure of all the speed clutches.
42
Power Train
Transmission Pressures
Table 13
Transmission Pressure
Pressure Pressure Tap Pressure at Low Idle Pressure at High Idle Adjustment
This pressure is identical to This pressure is identical to -
Oil Pump (H)
speed clutch pressure P1. speed clutch pressure P1.
The pressure is 530 ± 35 kPa Add spacers
(77 ± 5 psi) when the direction (34) or
Speed Clutch P1 -
(K) switch is in the NEUTRAL remove
(Initial Pressure)
position and plug (L) for the load spacers
piston is removed. (34).
This pressure is 2870 ± 135 kPa
This pressure must not be more (415 ± 20 psi) when the direction
than 480 kPa (70 psi) below the switch is in FORWARD or in -
Speed Clutch P1 (E)
pressure at high idle. Plug (L) for REVERSE and any speed is
the load piston is installed. selected. Plug (L) for the load
piston is installed.
This pressure is 2650 ± 135 kPa
This pressure must not be more (385 ± 20 psi) when the direction
than 480 kPa (70 psi) below the switch is in FORWARD or in -
Speed Clutch P1 (K)
pressure at high idle. Plug (L) for REVERSE and any speed is
the load piston is installed. selected. Plug (L) for the load
piston is installed.
This pressure is 2140 ± 170 kPa This pressure is 2230 ± 170 kPa
Direction Clutch P2 (G) (310 ± 25 psi). Plug (L) for the (325 ± 25 psi). Plug (L) for the -
load piston is installed. load piston is installed.
Transmission - This pressure is approximately -
(J)
Lubrication Oil 170 kPa (25 psi).
Adjustments for the Transmission Table 14
Pressures Pressure Change for the Valve(1)

Location
Pressure
Description Thickness of
Change
Spacers
5M-9622 1.58 mm 98 kPa
Spacer (34) (.062 inch) (14.2 psi)
Load
5M-9623 0.91 mm 57 kPa
Piston
Spacer (34) (.036 inch) (8.20 psi)
(20)
5M-9624 0.25 mm 16 kPa
Spacer (34) (.010 inch) (2.29 psi)
(1) Result of the addition of one spacer or the removal of one
spacer to the valve.
g00449583 i01405197
Illustration 26
Transmission Selector and Pressure Control Valve Solenoid Valve (Transmission
(20) Load piston. (34) Spacers.
Clutch) - Test
SMCS Code: 3174-081
This test will determine if the solenoid coil is

energized and the solenoid plunger is shifting in
order to permit the flow of oil.
43
Power Train
Hearing the click of a solenoid or using a 5. Place blocks in front of the wheels and behind
screwdriver to check that the solenoid coil is the wheels.
energized does not ensure that the solenoid plunger
has shifted. The following test will determine if the 6. Install the steering frame lock.
solenoid plunger is shifting.
Personal injury or death can result from sudden Table 15
machine movement.
Speed Range and Energized Engaged
Direction Solenoids Clutches
jury to persons on or near the machine. Third Speed Forward 3 and 2 3 and 2
Second Speed Forward 4 and 2 4 and 2
dure that follows before working on the machine. First Speed Forward 5 and 2 5 and 2
Neutral 3 3
First Speed Reverse 5 and 1 5 and 1
The input drive shaft rotates between the torque Second Speed Reverse 4 and 1 4 and 1
converter and the transmission whenever the en- Third Speed Reverse 3 and 1 3 and 1

NOTICE

products.

mandates.

g00740501
Illustration 27
Transmission
or in the operator’s sight. (D) Torque Converter Inlet Pressure Tap P3. (E) Speed Clutch
Pressure Tap P1. (G) Direction Clutch Pressure Tap P2. (J)
Transmission Lubrication Pressure Tap.

44
Power Train
10. Depress the right service brake pedal and

parking brake. Press the downshift gear speed
switch until the transmission is in first speed.
Watch the pressure gauge and move the STIC
transmission direction control switch from the
NEUTRAL position to the FORWARD position.
The needle on the pressure gauge should

drop. Then, the needle will return to the original
pressure reading. With the transmission in the
forward direction, press the upshift gear speed
switch through the remaining forward speed
positions and return the switch to first speed.
The same pressure drop should be noted in all
speeds. This checks the operation of all the
speed clutches.

Illustration 28 g00740506 12. Depress the right service brake pedal and
Transmission Selector and Pressure Control Valve
parking brake. Press the downshift gear speed
The transmission selector and pressure control valve is on the top
of the transmission. The transmission cover is removed.
switch until the transmission is in first speed.
Move the STIC transmission direction control
(K) Speed clutch pressure tap P1. (L) Plug for Load Piston LP.
switch to the FORWARD position.
Watch the pressure gauge and move the STIC

transmission direction control switch to the
REVERSE position. The needle on the pressure
gauge should drop. Then, the needle will return
to the original pressure reading. Now, move
the direction control switch to the FORWARD
position. The same pressure drop should be
observed. This checks the operation of both
direction clutches.

If a pressure drop is noted, the solenoid and the

related electrical circuit are functioning.
If a pressure drop is not noted, use a screwdriver

to check that the solenoid coil is energized. If the
screwdriver is attracted to the solenoid coil, this
indicates that the solenoid coil is energized. The
g00439183 problem is in the solenoid cartridge. The problem
Illustration 29
Location of Solenoid Valves could be a bent solenoid stem, a screen that is dirty
(1) Number 1 solenoid (Reverse). (2) Number 2 solenoid
or plugged, or a spring that is weak or broken.
(Forward). (3) Number 3 solenoid (Third speed). (4) Number 4
solenoid (Second speed). (5) Number 5 solenoid (First speed). If the screwdriver does not indicate that the solenoid
coil is energized, the problem is in the electrical
8. Install a hose and a 4130 kPa (600 psi) pressure circuit.
gauge on pressure tap (G).
Reference: For additional information on electrical
9. Engage the parking brake. Move the STIC system troubleshooting, refer to the Service
transmission direction control switch to the Manual module for Systems Operation, Testing
NEUTRAL position. Start the engine and operate and Adjusting, RENR2522, “Power Train Electronic
the engine at low idle. Control System”.
45
Power Train
i01405314
Speed Sensor (Transmission

Output) - Adjust
SMCS Code: 3175-025
Sudden movement or accidental starting of the

machine can cause personal injury or death to per-
sons on or near the machine.
To prevent personal injury or death, perform the

g00102610
following: Illustration 30
Transmission Output Speed Sensor
Park the machine on a smooth level surface. (1) Speed sensor. (2) Self-adjusting cap
Lower the bucket and or attachments to the Adjustment of Air Gap

ground.
1. Fully extend self-adjusting cap (2) to dimension
Stop the engine and engage the parking brake. A before installing the sensor.
Block the wheels and install the steering frame Dimension A .......................... 6.5 mm (.26 inch)
lock.
Note: The self-adjusting cap contacts the output
Turn the battery disconnect switch to the OFF po- gear when the sensor is installed. The air gap
sition and remove the key. between the sensor and the output gear is created
by runout.
Place a Special Instruction, SEHS7332, “Do Not
Operate” tag at the battery disconnect switch lo- 2. Torque sensor (1) to 25 ± 5 N·m (18 ± 4 lb ft)
cation to inform personnel that the machine is be- after installing the sensor in the torque converter
ing worked on. housing.
NOTICE

products.

mandates.
46
Power Train
i00829712
Limit Switch (STIC Control

Lock) - Adjust
SMCS Code: 3034-025-ZS
g00401738
Illustration 32
View A-A
Adjust switch assembly (1) until the wheel contacts

the small diameter of cam (2). Then loosen switch
assembly (1) by one turn in the opposite direction.
Tighten locknut (3).
(A) Distance between the wheel of switch assembly

(1) and locknut (3) ........... 27.0 mm (1.06 inch)
g00401718
Illustration 31
Front View
47
Power Train
i01406141
Bearing End Play (Rear Pump

Drive) - Adjust
SMCS Code: 3108-025-EP; 3108-028-BD
g00740272
Illustration 33
Note: Apply 7M-7260 Gasket Material on the seal Place the pump drive housing in the horizontal
bore surface which is in the case. Allow the gasket position for the following procedures.
material to dry before installing the seal. Make sure
that the gasket material is not applied to the lip Procedure for seating the bearings and adjusting
seal. Lubricate the lip seal with a minimal amount of the end play
the lubricant which is being sealed.
48
Power Train
1. Assemble the following components: the Note: Add the average thickness from Step 14 to
bearings, shaft (4), gear (1), gear (8), gear (9), the following values.
and gear (10).
gap (6) for bearing cage (7) ................. 0.15 mm
2. Remove the seal from bearing cages (3), (7), (.006 inch)
(12), and (13). Install bearing cages (3), (7),
(12), and (13). gap (11) for bearing cage (12) ............. 0.25 mm
(.010 inch)
3. Torque four bolts (2) in bearing cages (3) and
(7) to 34 N·m (25 lb ft). gap (14) for bearing cage (13) ............. 0.25 mm
(.010 inch)
Torque four bolts (2) in bearing cages (12) and
(13) to 34 N·m (25 lb ft). gap (5) for bearing cage (3) ................. 0.28 mm
(.011 inch)
Note: Torque the bolts in an alternating sequence
and repeat until all of the bolts are at the 16. Measure the end play for the output shafts.
recommended torque. The end play for the output shafts should be
0.12 ± 0.05 mm (.005 ± .002 inch).
4. Rotate the output shaft at least one revolution.
17. Install the seals in bearing cages (3), (7), (12),
5. Repeat Step 3 for a torque of 68 N·m (50 lb ft). and (13).
6. Rotate the output shaft at least one revolution. Reference: For additional information on adjusting
the rear pump drive, refer to the Service Manual
7. Repeat Step 5 and Step 6 until all of the bolts module Disassembly and Assembly, RENR2034,
are at a torque of 68 N·m (50 lb ft). “Power Train”, “Pump Drive (Rear) - Assemble”.
8. Loosen the bolts. Rotate the components in order

to be certain that the components have end play.
9. Torque four equally spaced bolts (2) in bearing

cages (3) and (7) to 3.4 N·m (30 lb in). Torque
four equally spaced bolts (2) in bearing cages
(12) and (13) to 2.3 N·m (20 lb in).
Note: Torque the bolts in an alternating sequence

and repeat until all of the bolts are at the
recommended torque.
10. Rotate the output shaft at least three revolutions.
11. Repeat Step 9 for the following torques: Torque

four equally spaced bolts (2) in bearing cages
(3) and (7) to 3.4 N·m (30 lb in). Torque four
equally spaced bolts (2) in bearing cages (12)
and (13) to 2.3 N·m (20 lb in).
12. Rotate the output shaft at least three revolutions.
13. Repeat Step 11 and Step 12 until the torque

does not change.
14. Measure the gap between the bearing cage

and the bearing housing at two points with a
standard feeler gauge. The points should be at
180 degree intervals on bearing cages (3), (7),
(12), and (13). Average the two measurements.
15. Install shims with the following thicknesses:

49
Power Train
i01407620
Bearing End Play (Drive Shaft

Support) - Adjust
SMCS Code: 3253-025-EP; 3253-025-BD
g00740875
Illustration 34
4. Install four of the twelve bolts (7) in the retainer.

Equally space the bolts. Evenly tighten the bolts
to 55 ± 10 N·m (40 ± 8 lb ft).
5. Measure the distance from the surface of retainer

(3) to the surface of cage (5). Use a depth
micrometer in order to make the measurement.
Make the measurement through the off positioned
hole.
6. Subtract the measurement on Step 5 from the

measurement on Step 1. The difference in the
measurements is the required thickness of
the shims (6). The shim pack must be within
0.025 mm (.0010 inch) of the required thickness.
7. Remove the four bolts (7) and retainer (3).
8. Install O-ring (4), required shims (6), and retainer

(3). Install 12 bolts (7). Tighten the 12 bolts
evenly to 55 ± 10 N·m (40± 8 lb ft).
g00740876
Illustration 35
Detail A
Note: The yokes and the universal joints must be

in-phase, as shown.
1. Measure thickness (2) of retainer (3) near the

off positioned hole.
2. Install bearings (1) into cage (5). The word

“thrust” has been engraved on the bearing race
of the inside diameter of both of the bearings.
Make sure that the bearings are assembled so
that the words “thrust” are adjacent.
3. Install retainer (3) without shims (6).

50
Power Train
i01408209 i01708959
Input Transfer Gears - Adjust Output Transfer Gears - Adjust

SMCS Code: 3159-025-BD; 3159-025-EP SMCS Code: 3159-025-EP; 3159-025-BD
g00741130
Illustration 36
1. Install coupling (1) and roller bearing assembly

(2).
2. Install seal retainer (4).
3. Measure gap (6) between the seal retainer and

bearing cage (5).
4. Install shims (3) in order to fill the gap between

the seal retainer and bearing cage, as needed.
g00741877
Illustration 37
51
Power Train
5. Tighten bolts (2) to a torque of 40 N·m (30 lb ft)

for a second time.
6. Repeat Step 4 and Step 5 until bolts (2) do

not move at a torque of 40 N·m (30 lb ft) and
the bearings are binding. The bearings are
binding if the gear does not turn freely after
three revolutions.
7. Loosen bolts (2) evenly. After bolts (2) are loose,

tighten the bolts finger tight. Do not move any
other part.
8. Use a tapered feeler gauge in order to measure

gap (1) between housing (8) and bearing cage
(4) in two places. Measure the gaps at 180
degree intervals.
9. To find the total thickness of the shims that are

required, add 0.05 mm (.002 inch) to the average
of the two measurements in Step 8.
10. Remove bearing cage (4).
11. Install the shims and bearing cage (4).
12. Install eleven bolts (2). Tighten the bolts to

105 ± 20 N·m (75 ± 15 lb ft).
g00741881
Illustration 38
13. Verify that gear (3) turns freely by rotating the
Adjustment Procedure for the gear.
Bearing End Play
Adjustment for the Upper Idler Gear
Note: Before the components are assembled,
make sure that the bearing cups are seated in the Desired end play ........................ 0.000 to 0.050 mm
housing and the bearing cage. Also, make sure (.0000 to .0020 inch)
that the bearing cones are seated against the gear
shoulders. Use a 0.038 mm (.0015 inch) shim or a 1. Horizontally position housing (8) with the opening
feeler gauge to verify that the bearing cups and for bearing cage (7) on the top. Place gear (5) in
cones are seated. the housing. Place bearing cage (7) without the
shims or the seals on housing (8).
Adjustment for the Input Gear 2. Install two bolts (9) at 180 degree intervals in
bearing cage (7). Tighten bolts (9) finger tight.
Desired end play ............................ .050 ± .025 mm
(.002 ± .001 inch) 3. Alternately tighten each bolt by one-fourth of
a turn. Tighten bolts (9) to a torque of 40 N·m
1. Horizontally position housing (8) with the opening (30 lb ft).
for bearing cage (4) on the top. Place gear (3) in
the housing. Place bearing cage (4) without the 4. Rotate gear (5) at least three revolutions or rotate
shims on housing (8). the gear until the gear turns freely.
2. Install two bolts and washers (2) at 180 degree 5. Tighten bolts (9) to a torque of 40 N·m (30 lb ft)
intervals in bearing cage (4). Tighten bolts (2) for a second time.
finger tight.
6. Repeat Step 4 and Step 5 until bolts (9) do
3. Alternately tighten each bolt by one-fourth of not move at a torque of 40 N·m (30 lb ft) and
a turn. Tighten bolts (2) to a torque of 40 N·m the bearings are binding. The bearings are
(30 lb ft). binding if the gear does not turn freely after
three revolutions.
4. Rotate gear (3) at least three revolutions or rotate
the gear until the gear turns freely.
52
Power Train
7. Loosen bolts (9) evenly. After bolts (9) are loose, 8. Use a tapered feeler gauge in order to measure
tighten the bolts finger tight. Do not move any gap (10) between housing (8) and bearing cage
other part. (14) in two places. Measure the gaps at 180
degree intervals.
8. Use a tapered feeler gauge in order to measure
gap (6) between housing (8) and bearing cage 9. To find the total thickness of the shims that are
(7) in two places. Measure the gaps at 180 required, add 0.05 mm (.002 inch) to the average
degree intervals. of the two measurements in Step 8.
9. To find the total thickness of the shims that are 10. Remove bearing cage (14).
required, add 0.025 mm (.0010 inch) to the
average of the two measurements in Step 8. 11. Install the shims and the O-ring. Install bearing
cage (14).
10. Remove bearing cage (7).
12. Install ten bolts (13). Tighten the bolts to
11. Install the shims and the O-ring. Install the 105 ± 20 N·m (75 ± 15 lb ft).
bearing cage (7).
13. To make sure that the gears turn freely, rotate
12. Install ten bolts (9). Tighten the bolts to gears (11) and (12).
105 ± 20 N·m (75 ± 15 lb ft).
13. To make sure that the gear turns freely, rotate

Adjustment for the Output Shaft
gear (5). Desired end play ........................ 0.075 ± 0.150 mm
(.0030 ± .0059 inch)
Adjustment for the Lower Idler Gear
Note: Remove bearing cage (18) from the housing
Desired end play ........................ 0.025 to 0.075 mm before performing the procedure that follows.
(.0010 to .0030 inch)
1. A tool is needed in order to align the two bearing
1. Horizontally position housing (8) with the opening cones. The tool consists of the following parts:
for bearing cage (14) on the top. Place gear (11)
in the housing. Place bearing cage (14) without (19) The length of sleeve (19) is 130.17 mm
the shims or the seals on housing (8). (5.125 inch). The diameter of the sleeve is
114.25 mm (4.50 inch).
2. Install two bolts (13) at 180 degree intervals in
bearing cage (14). Tighten bolts (13) finger tight. (20) Two 6Y-6681 Plates
3. Alternately tighten each bolt by one-fourth of a (21) 1D-4620 Bolt and 2J-3506 Full Nut
turn. Tighten bolts (13) to a torque of 40 N·m
(30 lb ft). 2. Position bearing cage (18) horizontally, as shown.
Refer to Illustration 38.
4. Rotate gears (11) and (12) at least three
revolutions or rotate the gears until the gears 3. Install the lower bearing cup in bearing cage
turn freely. (18). Before proceeding, make sure that the
bearing cup is seated. Use a 0.038 mm
5. Tighten bolts (13) to a torque of 40 N·m (30 lb ft) (.0015 inch) shim or a feeler gauge to verify that
for a second time. the bearing cup is seated.
6. Repeat Step 4 and Step 5 until bolts (13) do 4. Install the bearing cones and install the remaining
not move at a torque of 40 N·m (30 lb ft) and bearing cup into bearing cage (18).
the bearings are binding. The bearings are
binding if the gear does not turn freely after 5. Install the tooling. Tighten bolt (21) and the nut.
three revolutions.
6. Install retainer plate (22) and four bolts (23) at 90
7. Loosen bolts (13) evenly. After bolts (13) are degree intervals in bearing cage (18). Tighten
loose, tighten the bolts finger tight. Do not move bolts (23) finger tight.
any other part.
7. Alternately tighten each bolt by one-fourth of a
turn. Tighten bolts (23) to a torque of 15 N·m
(11 lb ft).
53
Power Train
8. Rotate the bearings at least three revolutions or 3. Use a torque wrench to measure the torque
rotate the bearings until the bearings turn freely. that is necessary to rotate the output shaft and
gears:(3), (5), (11), and (12). Record the torque
9. Tighten bolts (23) to a torque of 15 N·m (11 lb ft) value for reference.
for a second time.
4. Remove 0.10 mm (.004 inch) of the shims from
10. Repeat Step 8 and Step 9 until bolts (23) do the cage of the bearing that is being checked.
not move at a torque of 15 N·m (11 lb ft) and
the bearings are binding. The bearings are 5. Install the bearing cage with four equally spaced
binding if the gear does not turn freely after bolts. Tighten the bolts to a torque of 40 N·m
three revolutions. (30 lb ft).
11. Loosen bolts (23) evenly. Alternately loosen 6. Measure the rolling torque again and record the
each bolt by one-fourth of a turn. After bolts (23) value.
are loose, tighten the bolts finger tight. Do not
move any other part. 7. If the rolling torque in Step 6 is larger than the
rolling torque in Step 3, the shaft end play is
12. Use a tapered feeler gauge in order to measure correct. Remove the bearing cage and add the
gap (24) between retainer plate (22) and bearing shim that was removed in Step 4. Install the
cage (18) in four places. Measure the gaps at 90 bearing cage.
degree intervals.
8. If the rolling torque in Step 6 is identical to the
13. To find the total thickness of the shims that are rolling torque in Step 3, there is free play in the
required, add 0.35 mm (.014 inch) to the average gear. An error has been made in measuring.
of the four measurements in Step 12.
9. Repeat Step 4 through Step 6 until there is an
14. Remove retainer plate (22). increase in the rolling torque.
15. Install the shims and install the retainer plate 10. After the rolling torque has increased, add
(22). 0.05 mm (.002 inch) shims until the rolling
torque is identical to the rolling torque that was
16. Install ten bolts and washers (23). Apply measured in Step 3.
9S-3263 Thread Lock Compound to the
bolts prior to assembly. Tighten the bolts to 11. The end play is 0.00 to 0.05 mm
55 ± 10 N·m (40 ± 7 lb ft). (.000 to .002 inch) when the addition of
one 0.05 mm (.002 inch) shim causes the
17. Remove the tooling that was installed in Step 6. rolling torque to be equal to the value that was
measured in Step 3.
18. Install the gear and the spacer on the output
shaft. 12. Add shims for correct end play. Install the
bearing cage.
19. Install the output shaft in bearing cage (18).
20. Install yoke (16) and the plate. Tighten bolt (15).
21. To make sure that the output shaft turns freely,

rotate the output shaft.
22. Remove yoke (16) if the output shaft turns freely.

Install the lip seal. Install yoke (16).
23. Install the output shaft and the bearing cage

(18) on housing (8).
Optional Checking Procedure for

the End Play Adjustment
1. Loosen all the bearing cage bolts.
2. Turn the gears by using the bolt on the end of

the output shaft.
54
Power Train
i00831198 1. Put 5P-1730 Holding Fixture (2) in a vise and

tighten the vise.
Differential Pinion Preload -
Adjust
SMCS Code: 3254-025-ZP
g00103714
Illustration 41
2. Install retainer (3) on the 5P-1730 Holding

Fixture so that the notch in the retainer is aligned
g00103436 with the dowel on the holding fixture.
Illustration 39
(1) Housing Bolts

Torque for the eight bolts that fasten the
housings together ....................... 460 ± 70 N·m
(340 ± 50 lb ft)
Torque-turn after reaching the specified
torque ................................................. 180 ± 10
g00103716
Illustration 42
3. Install nut (4) (part of 5P-1730 Holding Fixture)

on the threaded end of holding fixture (2).
Tighten the nut against retainer (3) by hand.
g00103711
Illustration 40
55
Power Train
10. Bend the lock (13) so that the nut is held.
11. Remove nut (4).
12. Remove the pinion from the holding fixture.
13. Perform Step 1 through Step 12 for all four

pinions before you install the pinions in the
housing.
Note: After the pinions are installed in the differential

case, place the differential case in a vise. Rotate
one side gear clockwise for two revolutions. Then,
rotate the gear counterclockwise for two revolutions.
The torque that is needed to turn the assembled
gears must not be more than 50 N·m (37 lb ft).
g00103717
Illustration 43
4. Install bearing cup (8) and bearing cup (10) in

pinion (5).
5. Install bearing cone (11) and spacer (9) on

retainer (3).
6. Install pinion (5) on the retainer.
7. Install bearing cone (7) on the retainer.
8. Put the lock (13) in position on the retainer.
g00103718
Illustration 44
9. Install nut (6). While the pinion is turned slowly,

use 5P-0964 Spanner Wrench (12) and a
torque wrench to tighten the nut to a torque of
70 ± 15 N·m (52 ± 11 lb ft).
56
Power Train
i01410162
Differential Backlash and

Bearings - Adjust
SMCS Code: 3258-025-BKL
g00742427
Illustration 45
Differential and Bevel Gear
(1) Bevel pinion. (2) Nut. (3) Washer. (4) Bearing cone. (5) Bearing cup. (6) Housing. (7) Bearing cone. (8) Bearing cup. (9) Shims. (10) Carrier
assembly. (11) Bearing cup. (12) Bearing cone. (13) Differential group. (14) Bolts. (15) Bolts. (16) Adjusting nut lock. (17) Adjusting nut. (18)
Retainer. (19) Bevel gear. (20) Differential case. (21) Bolts. (22) Bearing cup. (23) Bearing cone. (24) Pin. (25) Shims. (26) Cover. (27) Bolts.
(28) Adjusting nut. (29) Bolts. (30) Adjusting nut lock. (A) Shim gap.
Note: The following procedure controls bearing 1. Install bevel gear (19) onto differential case
preload. The procedure provides the same results (20). Tighten the 36 bolts (21) to 375 ± 40 N·m
for new bearings and for used bearings. (275 ± 30 lb ft). After the torque is reached, turn
the bolts 120 ± 10 degrees.
57
Power Train
2. Install bearing cone (23) and bearing cone

(12) onto differential group (13). Make sure that
the bearing cone is fully seated. Lubricate the
bearing cone with SAE 50W differential oil.
3. Press bearing cup (8) and bearing cup (5) on

pinion housing (6). Make sure that the bearing
cups are fully seated.
4. Press bearing cone (7) on pinion (1). Make sure

that the bearing cone is fully seated. Lubricate
the bearing cone with SAE 50W differential oil.
5. Install pinion (1) in housing (6). Press bearing

cone (4) onto the pinion shaft. Allow a small
amount of end play to remain. Lubricate the
bearing cone with SAE 50W differential oil.
Note: If you freeze the bearing cups, allow the parts

to reach a uniform temperature. Then use a driver
or a press to reset the bearing cups. The limit for
freezing the bearing cups is −29C (−20F). Remove Illustration 46 g00103469
any frost and wipe the bearing cups dry. Lubricate Stake Nut and Tooling
the bearing cups with SAE 50W differential oil in
order to prevent rust on the bearing cups. 9. When the torque for rotating pinion (1) is correct,
stake nut (2) by peening the collar into the slot
Note: If you heat the bearing cones, allow the parts in the pinion shaft. Proper peening requires
to reach a uniform temperature. Then use a driver the use of a punch with a spherical nose. The
or a press to reset the bearing cones. The limit for punch should have a nose that is (C) diameter.
heating the bearing cones is a maximum of 135C The punch should be held at an angle (B). The
(275F) for a maximum of four hours. Lubricate the desired result is a stake of minimum length (D)
bearing cones with SAE 50W differential oil after and minimum depth (E). Refer to Illustration 46
the bearing cones have cooled in order to prevent for a view of a completed staked nut.
rust on the bearing cones.
List of dimensions for a staked nut
6. Secure the assembled pinion housing (6) in a
holding fixture. Install washer (3) and nut (2). Dimension (B) ................................. 10 to 30
Dimension (C) ........................ 7.5 to 8.0 mm
Table 16 (.30 to .32 inch)
Required Tools Dimension (D) ................. 4.7 mm (.19 inch)
Dimension (E) .................. 2.5 mm (.10 inch)
Part
Number
Note: The nut may be reused if the collar is not
1U-6691 Socket Wrench Assembly 1 cracked during removal or during restaking.
10. Secure carrier assembly (10) in a holding fixture.

7. While you rotate pinion shaft (1), tighten nut (2)
in order to achieve a preload rolling torque of
11. Install the pinion subassembly in carrier
2.3 to 5.1 N·m (20 to 45 lb in). This is the torque
assembly (10) with 80 percent of a new shim
that is needed in order to rotate pinion (1). Make
pack (9). Make sure that the axle centerline is
sure that there is zero end play of pinion shaft (1).
vertical and that the teeth of bevel gear (19) are
facing upward, as shown.
Note: Reduce the preload rolling torque to
1.15 to 2.55 N·m (10 to 23 lb in) for used roller
bearings with more than 100 hours of operation. 12. Tighten bolts (29) and (15) in each bearing cap
to a torque of 25 N·m (18 lb ft).
8. If the preload rolling torque for the pinion
exceeds the specifications, back off nut (2) by 13. Move adjusting nut (17) and adjusting nut (28)
to a position that maintains the gear backlash
1/8 turn and reseat bearing cone (4) and washer
and a slight bearing end play, but not a tight
(3) against nut (2). Perform step 7 again.
gear mesh.
58
Power Train
14. Reposition the differential assembly so that Tooth Contact Pattern Adjustment
the pinion shaft is vertical and the gear end is
downward.
(Pinion and Bevel Gear)
15. Measure the torque for rotating pinion (1) and
record the measured torque.
16. Move adjusting nut (28) to the zero backlash

position. Back off adjusting nut (28) by one-half
turn.
17. Move adjusting nut (17) while you rotate bevel

gear (19). Monitor the torque that is required to
rotate pinion (1) until the torque is greater than
the torque that was measured in step 15. This
is the seated position.
18. Move adjusting nut (17) until the torque for g00103470
Illustration 47
rotating pinion (1) is 5.6 N·m to 9.3 N·m
(50 lb in to 80 lb in).
1. After the backlash adjustment and the preload
adjustment have been made, check the tooth
19. Measure the backlash between bevel gear (19)
contact between pinion (1) and bevel gear (19)
and pinion gear (1). Measure the backlash at
by using the following procedure:
three equally spaced positions around the bevel
gear. The backlash must be 0.48 ± 0.15 mm
a. Put a small amount of Prussian blue, of red
(.019 ± .006 inch).
lead, or of paint on the teeth of bevel gear
(19).
20. If the backlash does not meet the specification
at any one of the three positions, back off one
b. Turn pinion (1) in both directions.
adjusting nut and move the other adjusting nut
forward by the same amount. This will maintain
c. The end of the correct area of tooth contact is
the bearing preload. Perform step 19 until the
near the inside end of the teeth of the bevel
backlash meets the specification at all of the
gear (19). The contact area should extend
three positions.
halfway across the length of the teeth. See
illustration 47 for the correct area of tooth
21. Measure the torque for rotating pinion (1).
contact.
The torque must be 5.6 N·m to 9.3 N·m
(50 lb in to 80 lb in).
22. Tighten bolts (15) and (29) in each bearing cap

to a torque of 460 ± 70 N·m (340 ± 50 lb ft).
After the torque is reached, turn the bolts 180
± 10 degrees.
23. Install adjusting nut locks (1) and (17).
g00103471
Illustration 48
2. If the area of tooth contact looks like Illustration

48, use the following procedure:
a. Remove some of the shims (9).
b. Perform step 14 through step 23 again.

59
Power Train
c. Perform step 2 and step 3 again in order to i01411863

check the area of tooth contact.
Wheel Bearings - Adjust
SMCS Code: 4051-025-BD
g00103472
Illustration 49
3. If the area of tooth contact looks like Illustration

49, use the following procedure:
a. Add some of the shims (9).
b. Perform step 14 through step 23 again.
c. Perform step 2 and step 3 again in order to Illustration 50 g00743184

check the area of tooth contact.
Final Drive and Wheel
Note: Always make sure that the backlash (1) Bolts. (2) Retainer. (3) Shims. (4) Hub. (5) Wheel bearings. (6)
Wheel. (7) Spacer. (8) Spindle.
adjustment is correct before an adjustment is made
to the area of tooth contact. Several adjustments
to the backlash and to the tooth contact may
be necessary in order to achieve the correct
adjustments.
4. Install pin (24) and cover (26) without shims (25).

Tighten bolts (27) enough in order to remove any
clearance between the pin and the cover.
5. Measure the distance between the face of the

cover (26) and the face of the axle housing.
Install the shims (25) so that the pin has an end
play of 0.03 to 0.08 mm (.001 inch to .003 inch).
6. Torque bolts (27) to 80 ± 15 N·m (60 ± 10 lb ft)

and then turn each bolt by an additional 120 ± 5
degrees in an alternating sequence.
7. Install retainer (18).
g00291914
Illustration 51
Bolt Tightening Sequence
(2) Retainer. (9) Gauge holes.
60
Power Train
This procedure requires a 25 to 50 mm (1 to 2 inch) 12. Remove bolts (1), retainer (2), hub (4), and
outside micrometer and a depth micrometer that wheel (6). Assemble the brake components and
has 50 mm (2 inch) of travel. the Duo-Cone seals on spindle (8). Make sure
that all of the contact surfaces are clean and dry
Note: The tire, the rim, and the brake components before installing the seals.
must be removed. The procedure that follows should
be performed in the horizontal position, but the Reference: For more information on installing
capability to rotate the wheel must be maintained. Duo-Cone seals, refer to the Service Manual
module Disassembly and Assembly, RENR2034,
1. Measure the thickness of retainer (2) with “Power Train”, “Duo-Cone Conventional Seals -
the outside micrometer. Measure the retainer Install”.
at three places near the three small gauge
holes (9). Record the average of these three 13. Install bolts (1), retainer (2), shims (3), hub
measurements. (4), and wheel (6). Torque the 20 bolts to
460 ± 70 N·m (340 ± 50 lb ft) and then turn each
2. Place spindle (8) on a support. The support can bolt by an additional 120 ± 5 degrees.
be the floor.
NOTICE
3. Apply lubricant to wheel bearings (5). Assemble The bolts should not be reused after the bolts have
spacer (7), wheel bearings (5), and wheel (6) been tightened to the recommended torque and then
on spindle (8). turned by an additional amount.
4. Install hub (4) and retainer (2) without shims (3).
Lubricate the threads of ten bolts (1). Install 10
bolts (1) in an equally spaced pattern.
5. Torque 10 bolts (1) to 250 ± 15 N·m

(185 ± 10 lb ft) in five equal steps of 50 N·m
(35 lb ft). Tighten the bolts in the sequence that
is shown in Illustration 51.
6. Rotate the wheel by one revolution. Make sure

that bolts (1) are tightened to 250 ± 15 N·m
(185 ± 10 lb ft).
7. Loosen 10 bolts (1) so that the wheel can slide a

slight amount downward on the wheel bearings.
8. Torque the 10 bolts (1) to 104 ± 5 N·m

(75 ± 4 lb ft) in five equal steps of 20 N·m
(15 lb ft). Tighten the bolts in the sequence that
is shown in Illustration 51.
9. Rotate the wheel by one revolution. Make sure

that bolts (1) are tightened to 104 ± 5 N·m
(75 ± 4 lb ft).
10. To measure the distance from the retainer to the

end of the spindle, use the depth micrometer.
Measure the distance through the three gauge
holes (9) in the retainer.
11. Record the average of the three depth

measurements. Subtract the average thickness
of the retainer that was measured in Step 1 from
the average depth that was measured in Step
10. The difference is the thickness of shims (3).
The thickness of shims (3) must be within ±
0.025 mm (.0010 inch) of the difference.
61
Power Train
Index Section
Index
B S
Bearing End Play (Drive Shaft Support) - Adjust... 49 Solenoid Valve (Transmission Clutch) - Test.......... 42
Bearing End Play (Rear Pump Drive) - Adjust....... 47 Speed Sensor (Transmission Output) - Adjust ...... 45
D T
Differential and Final Drive Troubleshooting .......... 19 Table of Contents................................................... 3

Operational Checks ........................................... 19 Testing and Adjusting ............................................ 21
Probable Causes of Problems in the Differential Testing and Adjusting Section ............................... 4
and Drive Axle.................................................. 20 Torque Converter Impeller Clutch Pressure - Test.. 25
Troubleshooting.................................................. 19 Maximum and Minimum Clutch Pressure .......... 28
Troubleshooting Problem List............................. 19 Torque Converter Inlet Pressure - Test.................. 21
Differential Backlash and Bearings - Adjust .......... 56 Torque Converter Lockup Clutch Pressure - Test .. 29
Tooth Contact Pattern Adjustment (Pinion and Lockup Clutch Disengaged (Minimum clutch
Bevel Gear) ...................................................... 58 pressure) .......................................................... 32
Differential Pinion Preload - Adjust........................ 54 Lockup Clutch Engaged (Maximum stabilized
pressure) .......................................................... 33
Torque Converter Outlet Pressure - Test ............... 22
G Torque Converter Stall - Test ................................. 36
Torque Converter Troubleshooting ........................ 8
General Information............................................... 4 Operational Checks ........................................... 10
Probable Causes of Problems in the Torque
Converter ......................................................... 11
I Troubleshooting.................................................. 10
Troubleshooting Problem List............................. 10
Important Safety Information ................................. 2 Transmission Pressures - Test and Adjust............. 37
Input Transfer Gears - Adjust................................. 50 Adjustments for the Transmission Pressures ..... 42
Test Procedures ................................................. 40
Transmission Pressures..................................... 42
L Transmission Troubleshooting ............................... 12
Operational Checks ........................................... 14
Limit Switch (STIC Control Lock) - Adjust ............. 46 Probable Causes of Transmission Problems ..... 15
Troubleshooting.................................................. 15
Troubleshooting Problem List............................. 14
M Troubleshooting ..................................................... 4
Machine Preparation for Troubleshooting .............. 5

V
O Visual Inspection ................................................... 6
Output Transfer Gears - Adjust .............................. 50

Adjustment for the Input Gear............................ 51 W
Adjustment for the Lower Idler Gear .................. 52
Adjustment for the Output Shaft......................... 52 Wheel Bearings - Adjust........................................ 59
Adjustment for the Upper Idler Gear .................. 51
Adjustment Procedure for the Bearing End
Play .................................................................. 51
Optional Checking Procedure for the End Play
Adjustment ....................................................... 53
Reduced Rimpull Pressure - Test .......................... 33

62
Power Train
Index Section
63
Power Train
Index Section
©2002 Caterpillar
All Rights Reserved Printed in U.S.A.

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RENR2506-05

Testing and Adjusting

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Testing and Adjusting

Testing and Adjusting

i01397515 Always use a board or cardboard when checking

Note: This machine is equipped with a power train

Reference: For more information on the

2. Perform visual checks. If the visual checks

1. Move the machine to a smooth, horizontal

3. Move the work tool until the bottom of the work

a. Air bubbles may be caused by a fitting that is

Note: If any of these particles are found during any

5. The drive shafts and universal joints must rotate

Probable causes: Problem: The torque converter does not respond

4. The impeller clutch solenoid or the modulating

5. There is a problem in the electrical circuit.

Problem: The lockup clutch does not engage.

1. The on/off switch for the lockup clutch is not in

2. The on/off switch for the lockup clutch is faulty.

3. The lockup clutch solenoid or the modulating

4. The torque converter output speed sensor is

5. There is a problem in the electrical circuit.

6. There is excessive leakage in the lockup clutch.

7. The magnetic screens are plugged. The oil flow

8. The lockup clutch is damaged.

9. The power train oil pump is damaged.

Problem: The impeller clutch does not engage.

1. The impeller clutch solenoid or the modulating

2. There is a problem in the electrical circuit.

3. There is excessive leakage in the impeller clutch.

4. The impeller clutch is damaged.

5. The magnetic screens are plugged. The oil flow

6. The power train oil pump is damaged.

Dispose of all fluids according to local regulations and

Hydraulic oil pressure can remain in the hydraulic Operational Checks

• The transmission overheats.

• The transmission does not operate in SECOND

f. Modulating relief valve (13) is stuck open.

1. Coolant level in the radiator is low. Probable causes:

a. Low oil pressure. Refer to the Problem: The Probable causes:

Probable causes: 3. The FORWARD clutch is not engaged or the

Probable causes: c. Clutch components are broken.

2. Load piston (20) is stuck. Probable causes:

Problem: The pressure differential between P1 Probable causes:

Probable causes: 5. Gears in the transmission do not turn because

Probable causes: 2. The backup alarm has failed.

Problem: Stall speed is high when the machine is

Testing and Adjusting

Torque Converter Inlet

5. Place blocks in front of the wheels and behind

6. Install the steering frame lock.

7. Allow only authorized personnel on the machine.

NOTICE 3. The pressure on the gauge must not exceed

Refer to Special Publication, NENG2500, “Caterpillar

1. Move the machine to a smooth, horizontal

Note: Permit only one operator on the machine.

2. Move the STIC transmission direction control

3. Lower the work tool to the ground.

4. Engage the parking brake.

4. Engage the parking brake.