WHEEL LOADER AYT Configuration: 980G SERIES II WHEEL LOADER AYT00001-UP (MACHINE) POWERED BY 3406E Disassembly and Assembly 980G Series II Wheel Loader Power Train Media Number -RENR4378-05 Publication Date -01/01/2004 Date Updated -14/01/2004 i05903287 Torque Converter (Freewheel Stator) - Disassemble SMCS - 3101-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 B 8B-7548 Push-Puller 1 8B-7550 Leg 2 8H-0684 Ratchet Wrench 1 8B-7560 Step Plate 1 8H-0663 Bearing Puller Attachment 1 C 8B-7548 Push-Puller 1 8H-0684 Ratchet Wrench 1 8B-7549 Leg 2 5P-4808 Cap 2 8B-7554 Bearing Cup Puller Attachment 1 D 5F-7343 Bearing Puller Attachment 1 1P-0520 Driver Group 1 E 1P-0510 Driver Group 1 F 7
A. Separate the torque converter from the transmission and from the output transfer gears. Refer to Disassembly and Assembly, "Torque Converter from Transmission, Output Transfer Gears - Separate" for the machine that is being serviced. 1. Place the torque converter housing assembly (2) on wood blocks. Illustration 1 g00503225 2. Remove bolts (1) and the washers from torque converter housing assembly (2) . Illustration 2 g01111329 3. Install Tooling (A) to torque converter housing assembly (2) , as shown. Attach a suitable lifting device to Tooling (A) . The weight of housing assembly (2) is approximately 120 kg (265 lb). 4. Use Tooling (F) to loosen housing assembly (2) from the torque converter.
adapter (5) from torque converter housing assembly (2) . Illustration 6 g00871319 9. Use tooling (C) to remove bearing cup (6) , O-ring seal (8) , and shims (7) from pump adapter (5) . See illustration 13 for Tooling (C) . Illustration 7 g00871326
assembly (2) . Illustration 8 g00871451 11. Use Tooling (B) to remove bearing cones (10) from each side to pump drive gear (9) . Illustration 9 g00871333 12. Use Tooling (C) to remove bearing cup (11) from torque converter housing assembly (2) . See illustration 13 for Tooling (C) .
carrier (25) . 26. Remove seal ring (27) from ring carrier (28) . Illustration 21 g00871273 27. Use Tooling (D) and a press to remove ring carrier (28) from bearing carrier (25) .
(35) and rotating housing (36) . Illustration 28 g00871281 35. Use bolts (34) as forcing screws to remove drive flange (35) from rotating housing (36) . The weight of drive flange (35) is 23 kg (51 lb). Illustration 29 g00871282 36. Remove bolts (37) from drive flange (35) .
from carrier assembly (41) . Illustration 33 g00870211 41. Remove carrier assembly (41) and stator (42) as a unit from rotating housing (36) . Illustration 34 g00870212 42. Remove snap ring (43) from stator (42) . Remove plate (44) from stator (42) .
11 freewheel springs (46) from freewheel cam (47) . Remove stator (42) from carrier assembly (41) . Illustration 36 g01112915 44. Remove retaining ring (48) . Remove plate (49) . 45. Use Tooling (E) and a hydraulic press in order to remove freewheel cam (47) from stator (42) . Note: If necessary, heat the stator to a maximum temperature of 135 °C (275 °F) for approximately 15 minutes. Illustration 37 g01112917 46. Remove thrust bearing (50) from carrier assembly (41) . Remove sleeve bearing (51) from carrier assembly (41) .
the thrust bearing. Illustration 39 g00870286 48. Remove turbine (53) and turbine hub (54) as a unit from rotating housing (36) . Illustration 40 g01112920 49. Remove bolts (55) and the washers that hold turbine (53) to hub (54) .
WHEEL LOADER AYT Configuration: 980G SERIES II WHEEL LOADER AYT00001-UP (MACHINE) POWERED BY 3406E Disassembly and Assembly 980G Series II Wheel Loader Power Train Media Number -RENR4378-05 Publication Date -01/01/2004 Date Updated -14/01/2004 i05903427 Torque Converter (Freewheel Stator) - Assemble SMCS - 3101-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7573 Link Bracket 3 G 8T-5096 Dial Indicator Test Group 1 5P-2390 Gauge Tool Group 1 H 1P-0520 Driver Group 1 J - Guide Pin (3/8 - 16 by 8 in) 2 K - Guide Pin (1/2 - 13 by 3 in) 3 L 2P-8312 Retaining Ring Pliers 1 Note: Cleanliness is an important factor. Before assembly, thoroughly cleaned in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts. Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement. Note: Apply oil to all of the bearings before assembly.
bearing (62) in cover assembly (60) . Sleeve bearing (62) must be even with the outside surface of cover assembly (60) . Illustration 2 g03337064 2. Install ring seal (61) to rotating housing (36) . 3. Install cover assembly (60) to rotating housing (36) . 4. Install bolts (59) and the washers to cover assembly (60) . Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft).
to turbine (53) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Illustration 7 g00870759 9. Install hub (54) and turbine (53) as a unit to rotating housing (36) .
the bearing to the turbine hub (54) . Illustration 9 g01112941 11. Use Tooling (H) and a hydraulic press in order to install sleeve bearing (51) to carrier assembly (41) . Install thrust bearing (50) to carrier assembly (41) . Illustration 10 g01112915
press in order to install freewheel cam (47) to stator (42) . 13. Install plate (49) to stator (42) . Install retaining ring (48) to stator (42) . Note: If necessary, heat stator (42) to a maximum temperature of 135 °C (275 °F). Install the cam with the IMPELLER SIDE facing downward. Continue with the installation until freewheel cam (47) contacts the retaining ring (not shown). 14. Install stator (42) to carrier assembly (41) . Install freewheel springs (46) and freewheel rollers (45) to freewheel cam (47) . Always install new freewheel springs (46) and freewheel rollers (45) . Install freewheel springs (46) with the maximum number of loops in freewheel springs (46) to the outside of freewheel cam (47) . Use the orientation of stator (42) in Illustration 11 in reference to the following statement: Stator (42) should turn freely in the clockwise direction. Stator (42) should not turn freely in the counterclockwise direction. Illustration 12 g00870421 15. Install plate (44) to stator (42) . Install snap ring (43) to stator (42) .
(42) as a unit to rotating housing (36) . Illustration 14 g00870762 17. Install thrust bearing (40) and race (40A) (not shown) to the carrier assembly (41) . Illustration 15 g00870994 18. Position impeller hub (39) on a wood block.
housing (36) . The weight of drive flange (35) is approximately 23 kg (51 lb). 23. Install bolts (34) and the washers to drive flange (35) . Tighten the bolts to a torque of 30 ± 5 N·m (22 ± 4 lb ft). Illustration 19 g00871003 24. Install retaining ring (33) in the groove of drive gear (32) .
outer bearing race (32A) . Lower the temperature of outer bearing race (32A) . 26. Install outer bearing race (32A) in drive gear (32) . Make sure that outer bearing race (32A) contact retaining ring (33) . Illustration 21 g00870763 27. Install drive gear (32) on drive flange (35) . 28. Install bolts (31) and the washers on drive gear (32) . Tighten the bolts to a torque of 50 ± 7 N·m (37 ± 5 lb ft). Illustration 22 g00871006 29. Use the proper equipment to handle inner bearing (30) . Heat inner bearing (30) to a maximum temperature of 135 °C (275 °F). Install inner bearing (30) on bearing carrier (25) .
groove of bearing carrier (25) . Illustration 24 g00871009 31. Use the proper equipment to handle ring carrier (28) . Heat ring carrier (28) to a maximum temperature of 135 °C (275 °F). Install ring carrier (28) on bearing carrier (25) . Illustration 25 g00871012
housing assembly (2) . Tighten the studs to a torque of 100 ± 15 N·m (74 ± 11 lb ft). Illustration 29 g00872711 37. Install retaining ring (21) in the groove of idler gear (13) . Illustration 30 g00872713
. Lower the temperature of bearing cup (22) . Install bearing cup (22) in idler gear (13) . Illustration 31 g00872715 39. Flip idler gear (13) to the opposite side. Install bearing cup spacer (20) in idler gear (13) . The notch in bearing cup spacer (20) must be aligned with retaining ring (21) . Illustration 32 g00872716 40. Use the proper equipment to handle bearing cup (19) . Lower the temperature of bearing cup (19) . Install bearing cup (19) in idler gear (13) .
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Hold idler gear (13) in position in torque converter housing assembly (2) . Install shaft assembly (15) . 45. Remove Tooling (K) from shaft assembly (14) . Illustration 36 g01112970 46. Install bolt (12) that holds shaft assembly (14) in place in torque converter housing assembly (2) . Tighten the bolt to a torque of 120 ± 20 N·m (90 ± 15 lb ft). Illustration 37 g00872724 47. Use the proper equipment to handle bearing cones (10) . Heat bearing cones to a maximum temperature of 135 °C (275 °F). Install a bearing cone (10) on each side of pump drive gear (9) .
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