GEAR GP-FRONT 2004496 - Caterpillar

Illustration 19 g01143120
Use Tooling (E) to install lip seal (38) into drive housing (5).
Illustration 20 g01143123
Apply Tooling (F) to bearing (37) and install the bearing into the drive housing.
Install spring seat (36) into the drive housing.
Illustration 21 g00925068
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.
Install return spring (16) onto the spring seat inside drive housing (5).
Install the drive gear, the piston, and the drive shaft onto the return spring as a unit. Install retaining ring (15) over the piston. Place Tooling (B) between the drive gear and piston (14). Use a suitable press to compress return spring (16). Install retaining ring (15) into the groove of the drive housing. Slowly release the press and remove Tooling (B).
Illustration 22 g00925061
Install O-ring seal (13) to drive housing (5).
Illustration 23 g00925105
Apply Tooling (F) to bearing (34) and install bearing (34) into gear case (6). Use Tooling (C) to install lock ring (35).
Illustration 24 g01143454
Install drive housing (5) on gear case (6). Make sure that the shaft on the end of the drive gear is correctly engaged with the bearing in the gear case. Install bolts (12) and tighten to a torque of 36 N m (27 lb ft).
Illustration 25 g00925470
Use Tooling (A) to install retaining ring (8).
Illustration 26 g01143442
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.
Note: Bolt (9) has left hand threads.
Install pinion spring (62), spring sleeve (61), and drive pinion (11). Install washer (10) and bolt (9). Tighten bolt (9) to a torque of 110 N m (80 lb ft). Note: Bolt (9) has left hand threads.
Illustration 27 g00925012
Install gear case (6) and drive housing (5) onto motor housing (3). Install bolts (4) and tighten evenly to a torque of 80 N m (60 lb ft).
Illustration 28 g00925011
Install the gasket, elbow (1), and bracket (2) on motor housing (3).
After you verify that the starting motor operates properly, attach the air lines to the starting motor. Verify the Operation of the Air Starting Motor
Use the following procedure to verify that the air starting motor is operating correctly:
Turn the drive pinion by hand in the direction of the rotation of the starting motor. The drive clutch must operate smoothly with a clicking sound.
Turn the drive pinion in the opposite direction of the rotation of the starting motor. The drive pinion must turn by hand.
Apply 345 kPa (50 psi) of air pressure in the inlet of the drive housing. The drive pinion must move away from the drive housing and air must come out of the outlet of the drive housing.
Plug the outlet of the drive housing. Apply 1034 kPa (150 psi) of air pressure in the inlet of the drive housing. Ensure that no air is leaking. Measure the dimension from the face of the drive pinion to the mounting face of the drive housing. The dimension must be 73.00 2.0 mm (2.874 0.08 inch). Remove the air