ENGINE AR 1W9220 - Caterpillar

Start by:a. Remove differentials and pinion assemblies. The disassembly and assembly procedures are the same for the front and rear pinion assemblies. 1. Remove six bolts (1) and the washers that hold retainer (2) to the pinion housing. Remove the retainer. 2. Remove lip-type seal (3) from retainer (2). 3. Bend crimp (4) away from the slot in the pinion shaft with a hammer and punch.4. Use tooling (A) to remove nut (5) from the pinion shaft. 5. Using a press, remove pinion shaft (6) from the pinion housing. 6. Remove bearing cone (10) and bearing cups (8) and (9) from the pinion housing. Remove bearing cone (7) from the pinion shaft. The following steps are for the assembly of the pinion assemblies. Cup freezing or cone heating may be used if cups or cones are reset with a driver or press after parts have reached a uniform temperature. Limit cone heating to 135°C (275°F) maximum for a maximum of 4 hours. Lubricate bearings after they have cooled to prevent rusting.7. Install bearing cups (8) and (9) in pinion housing (11). Bearing cups must be seated against the shoulders in pinion housing (11).8. Install bearing cone (7) on pinion (6). Bearing cone (7) must be seated against the shoulder on pinion (6). Lubricate bearing cone (7).9. Install pinion (6) in housing (11). Press bearing cone (10) into place leaving a small amount of endplay. Lubricate bearing cone (10). Lubricate and install the washer and nut (5).10. Position the assembly vertically in a soft jawed vise. Tighten the vise against the teeth on pinion (6). Tighten an appropriate bolt and nut through an outer mounting bolt hole in pinion housing (11).11. Place a 203 mm (8.0 in) torque wrench on this bolt so that it is in line with the center of pinion shaft (6).12. While turning housing (11) with the torque wrench, tighten nut (5) until the torque wrench reading in the following chart is reached. Check to be sure that there is zero end play of pinion shaft (6). 13. If pinion rolling torque exceeds the specification, back off nut (5) 1/8 turn and reseat bearing cone (10) and the washer against nut (5). Perform Steps 11 and 12 again. If any other length torque wrench is used, find the torque wrench reading by using the following formula: C = (B × T)/(B + A)Where:"C" is the reading on the torque wrench (in N m)."B" is the length of the torque wrench (in meters)."A" is the bolt circle radius of pinion housing (9) in meters and is equal to 0.120 m (4.72 in)."T" is the rolling torque specification for pinion bearing preload which is 0.7 to 1.1 N m (6 to 10 lb in).
Illustration A14. When the torque needed to turn the pinion is correct, stake nut (5) by peening the collar on the nut into the key slot in pinion shaft (6). See Illustration A for the correct tooling and dimensions. The nut may be reused