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Desarmado y Armado
789C Off-Highway Truck/Tractor Power Train
Número de medio -SENR1524-07 Fecha de publicación -01/02/2005 Fecha de actualización -14/02/2005

i01958922

Torque Converter - Assemble


SMCS - 3101-016

Assembly Procedure
Table 1

Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
B 0S-1618 Bolt 1
D 1P-0520 Driver Group 1
E 138-7573 Link Bracket 3
F 1P-7409 Eyebolt 2

1. Verify that all of the components and the O-ring seals are clean and free of foreign material prior
to assembly.

2. Inspect all components for wear and replace the components, if necessary.

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Illustration 1 g00630301

3. Raise the temperature of inner bearing (77) to a temperature of 135 °C (275 °F). Install inner
bearing (77) and snap ring (76) on stator carrier (62) .

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Illustration 2 g00631192

4. Install two seal rings (75) on stator carrier (62) .

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Illustration 3 g00630303

5. Raise the temperature of ring carrier (73) to a temperature of 135 °C (275 °F). Install ring carrier
(73) on output shaft (69). Use a brass drift to be certain that ring carrier (73) is properly seated.

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Illustration 4 g00630306

6. Raise the temperature of ball bearing (74) to a temperature of 135 °C (275 °F). Install ball bearing
(74) on output shaft (69). Use a brass drift to be certain that ball bearing (74) is properly seated.

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Illustration 5 g00630308

7. Raise the temperature of ring carrier (71) to a temperature of 135 °C (275 °F). Install ring carrier
(71) on output shaft (69). Use a brass drift to be certain that ring carrier (71) is properly seated.

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Illustration 6 g00631188

8. Install two seal rings (70) on ring carrier (71). Install seal ring (72) (not shown) on ring carrier
(73) .

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Illustration 7 g00630311

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Illustration 8 g00630313

9. Position stator carrier (62) on a suitable stand. Install Tool (F) to output shaft (69), as shown.
Attach a suitable lifting device to Tool (F). Secure the lifting device to a hoist. Lower output shaft
(69) into stator carrier (62). If necessary, use a soft faced hammer to seat the bearing against the
shoulder in stator carrier (62) .

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Illustration 9 g00631182

10. Apply 1U-6396 O-Ring Assembly Compound to the O-ring seal. Install sensor rotor (67), plug
(68), and the O-ring seal in distributor (64) .

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Illustration 10 g00630315

11. Use Tool (D) to install a new lip seal (66) on distributor (64) .

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Illustration 11 g00631180

12. Install gasket (65) on stator carrier (62) .

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Illustration 12 g00631177

13. Install distributor (64), 12 bolts (63) and the washers on stator carrier (62). Tighten 12 bolts (63)
to a torque of 50 ± 7 N·m (37 ± 5 lb ft).

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Illustration 13 g00631170

14. Turn over the assembly. The weight of the assembly is 329 kg (725 lb). Install freewheel race
(61), split washer (60) and six bolts (59). Tighten six bolts (59) to a torque of 30 ± 5 N·m (22 ± 4
lb ft).

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Illustration 14 g00630323

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Illustration 15 g00630324

15. Install O-ring seal (55) on drive flange (51). Use a suitable driver to install sleeve (58) into drive
flange (51) .

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Illustration 16 g00630327

16. Turn over drive flange (51). Drive flange (51) weighs 57 kg (126 lb). Install pump drive gear (57)
and 12 bolts (56) on drive flange (51). Tighten 12 bolts (56) to a torque of 50 ± 7 N·m (37 ± 5 lb
ft).

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Illustration 17 g00631163

17. Use two people in order to install impeller (50) on drive flange (51). Impeller (50) weighs 25 kg
(55 lb).

Note: During the installation of impeller (50), be certain that the identification marks are aligned.

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Illustration 18 g00631162

18. Install O-ring seal (54) on impeller hub (49) .

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Illustration 19 g00631159

19. Install thrust race (53) on impeller hub (49) .

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Illustration 20 g00631157

20. Install impeller hub (49) and eight bolts (52) on impeller (50). Tighten eight bolts (52) to a torque
of 80 ± 10 N·m (59 ± 7 lb ft).

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Illustration 21 g01017815

21. Install Tooling (A) to drive flange (51), as shown. Attach a suitable lifting device to Tooling (A).
Secure the lifting device to a hoist. Install impeller (50) and drive flange (51) on the output shaft.
The combined weight of impeller (50) and drive flange (51) is 84 kg (185 lb).

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Illustration 22 g00631152

22. Install needle bearing (48) on impeller hub (49) .

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Illustration 23 g00631133

23. Use Tool (D) and a suitable press to install bearing sleeve (47) (not shown) into race (44). After
assembly, the diameter of the bearing bore must be 127.19 ± .02 mm (5.008 ± 0.001 inch).

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Illustration 24 g00630346

24. Install retaining ring (45) in converter stator (38) .

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Illustration 25 g00630348

25. Raise the temperature of converter stator (38) to a temperature of 135 °C (275 °F). Install race
(44) into converter stator (38). Use a suitable brass drift to stake converter stator (38) in two
places in order to retain race (44) .

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Illustration 26 g00630353

26. Turn over converter stator (38). Install freewheel cam (48) in converter stator (38) .

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Illustration 27 g00630390

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure


and wear protective equipment.

27. Install two springs (43) and roller cage (42) in converter stator (38) .

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Illustration 28 g00631123

28. Install 24 freewheel rollers (41) in roller cage (42) .

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Illustration 29 g00631122

29. Use Tool (D) and a suitable press to install bearing sleeve (40) (not shown) into bearing support
(37). The bearing bore must be 127.19 ± .08 mm (5.008 ± 0.003 inch).

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Illustration 30 g01017814

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Illustration 31 g01017812

30. Install Tooling (E) to converter stator (38), as shown. Attach a suitable lifting device to Tooling
(E). Secure the lifting device to a hoist.

31. Install bearing support (37) and five bolts (39). Tighten five bolts (39) to a torque of 30 ± 5 N·m
(22 ± 4 lb ft).

32. Install converter stator (38) on the converter turbine.

33. Remove Tooling (E). Install three remaining bolts (39). Tighten three bolts (39) to a torque of 30
± 5 N·m (22 ± 4 lb ft).

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Illustration 32 g00631115

34. Install needle bearing (36) on bearing support (37) .

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Illustration 33 g00631111

35. Install wear sleeve (33). Install seal ring (34) and plug (35) on clutch housing (24). Use a suitable
brass drift to be certain that wear sleeve (33) is properly seated.

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Illustration 34 g00631100

36. Install seal ring (28) on ring carrier (26) .

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Illustration 35 g00630392

37. Install ring carrier (26) on hub (25) .

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Illustration 36 g00631102

38. Lubricate seal ring (30) with the lubricant that is being sealed. Install seal ring (30) on clutch
piston (29) .

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Illustration 37 g00630425

39. Install clutch piston (29) on hub (25) .

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Illustration 38 g01018185

40. Install Tooling (A) to clutch housing (24), as shown. Attach a suitable lifting device to Tooling
(A). Secure the lifting device to a hoist. Lower clutch housing (24) on clutch piston (29) and hub
(25). Clutch housing (24) weighs 68 kg (150 lb).

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Illustration 39 g00630432

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Illustration 40 g00630436

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Illustration 41 g00630437

NOTICE
Pay attention to the orientation of the bearings. The bearings must be
properly installed. If the bearings are improperly installed, premature
failure of the bearings will occur.

41. Install bearings (31) and (32) in clutch housing (24). Use a suitable driver to be certain that
bearings (31) and (32) are properly seated.

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Illustration 42 g00630438

42. Use a screwdriver to install locking ring (27) in hub (25) .

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Illustration 43 g00631010

Personal injury or death can occur from heavy components falling


during removal or installation.

Properly support the component with a suitable lifting device during


removal or installation.

43. Install Tool (B) in order to prevent hub (25) from falling.

Note: Tool (B) must be installed in the hub in order to prevent the hub and the turbine assembly

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from falling.

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Illustration 44 g00630442

44. Turn over clutch housing (24). Install four friction discs (26) and three clutch plates (27) .

Note: Begin the installation procedure with a friction disc. Next, install a clutch plate. Continue to
install the discs and the plates in this order. Install a friction disc last.

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Illustration 45 g00631007

45. Install pipe plug (23) in rotating housing (12) .

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Illustration 46 g01017804

46. Install Tooling (C) to rotating housing (12), as shown. Attach a suitable lifting device to Tooling
(C). Secure the lifting device to a suitable hoist. Lower rotating housing (12) on clutch housing
(24). Rotating housing (12) weighs approximately 59 kg (130 lb).

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Illustration 47 g00631002

47. Install 26 bolts (22) and the washers. Tighten 26 bolts (22) to a torque of 240 ± 25 N·m (177 ± 18
lb ft).

Note: Initially tighten two bolts (22) that are separated by 180 degrees. Rotate 45° ± 12° until
eight bolts (22) are tightened. Tighten all bolts (22) .

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Illustration 48 g00630997

48. Use two people to install turbine (19) in rotating housing (12). Turbine (19) weighs 27 kg (60 lb).

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Illustration 49 g00630995

49. Install two dowels (21) in support (15) .

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Illustration 50 g00630948

50. Use Tool (D) and a suitable press to install bearing sleeve (20) in support (15) .

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Illustration 51 g00630881

Improper assembly of parts that are spring loaded can cause bodily
injury.

To prevent possible injury, follow the established assembly procedure


and wear protective equipment.

51. Lower the temperature of support (15) to a temperature of -75 °C (-103 °F). Install support (15) in
turbine (19). Install eight springs (18) in support (15) .

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Illustration 52 g00630878

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Illustration 53 g00630877

52. Install thrust race (17), the two washers and two bolts (16) on support (15) .

Note: When bolts (16) are tightened, evenly compress the springs behind thrust race (17) .

53. Install 10 twelve point head bolts (14) and the washers into rotating housing (12). Tighten 10
twelve point head bolts (14) and two bolts (16) to a torque of 80 ± 10 N·m (59 ± 7 lb ft).

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Illustration 54 g00630869

54. Install Tooling (A) to rotating housing (12) (not shown). Attach a suitable lifting device to
Tooling (A). Secure the lifting device to a hoist. Install rotating housing (12) on the torque
converter. Rotating housing (12) weighs 227 kg (500 lb). Install 30 bolts (13) and the washers.
Tighten 30 bolts (13) to a torque of 135 ± 15 N·m (100 ± 11 lb ft).

Note: Initially tighten two bolts (13) that are separated by 180 degrees. Rotate 45° ± 12° until
eight bolts (13) are tightened. Tighten all bolts (13) .

Note: Be certain that the identification marks are aligned.

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Illustration 55 g00630443

55. Remove Tool (B) from hub (25) .

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Illustration 56 g00630826

56. Install the spring washer and retainer plate (11). Install three bolts (10). Tighten bolts (10) to a
torque of 240 ± 25 N·m (177 ± 18 lb ft).

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Illustration 57 g00630447

57. Install Tooling (A) to the torque converter, as shown. Attach a suitable lifting device to Tooling
(A). Secure the lifting device to a hoist. Install flywheel pilot (9), the washers and ten bolts (8).
Tighten bolts (8) to a torque of 120 ± 15 N·m (90 ± 11 lb ft).

58. Remove the torque converter from the stand.

59. Remove Tooling (A). Install two remaining bolts (8) and the washers. Tighten two bolts (8) to a
torque of 120 ± 15 N·m (90 ± 11 lb ft).

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Illustration 58 g00630814

60. Install yoke assembly (7) on the torque converter.

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Illustration 59 g00630813

61. Install O-ring seal (6) on the torque converter.

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Illustration 60 g00630809

62. Install retainer (5) and bolt (4) on the torque converter.

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Illustration 61 g00630757

63. Install two O-ring seals (3) on the torque converter.

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Illustration 62 g00627485

64. Install Tooling (A) (not shown) to torque converter housing assembly (2). Attach a suitable lifting
device to Tooling (A). Secure the lifting device to a hoist.

65. Install torque converter housing assembly (2) to the torque converter. The weight of torque
converter housing assembly (2) is 193 kg (425 lb).

66. Install 17 bolts (1) and the hard washers to the torque converter.

End By:

a. Install the suction screen (torque converter sump). Refer to Disassembly and Assembly, "Suction
Screen (Torque Converter Sump) - Install".
b. Install the lockup clutch and synchronizing valve of the torque converter. Refer to Disassembly
and Assembly, "Lockup Clutch and Synchronizing Valve (Torque Converter) - Install".
c. Install the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Relief Valve
(Torque Converter Outlet) - Install".
d. Install the torque converter inlet relief valve. Refer to Disassembly and Assembly, "Relief Valve
(Torque Converter Inlet) - Install".
e. Install the transmission pump. Refer to Disassembly and Assembly, "Gear Pump (Transmission) -
Install".
f. Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Install".

Copyright 1993 - 2008 Caterpillar Inc. Tue Apr 8 12:39:00 UTC-0400 2008
Todos los derechos reservados.
Red privada para licenciados del SIS.

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