assembly and Assembly

776D Wheeled Tractor and

777D and 777D HAA Off-Highway Trucks Power Train

Media Number -RENR3366-07 Publication Date -01/08/2008 Date Updated -18/08/2008

i07416068

Transmission Planetary - Assemble

SMCS - 3160-016

Assembly Procedure
Table 1
Required Tools

Tool Part Number Part Description Qty

A 1P-2420 Transmission Repair Stand 1

B 1P-1863 Retaining Ring Pliers 1

C 138-7573 Link Bracket 2

D 1P-0520 Driver Group 1

F 138-7576 Link Bracket 1

G 2P-8312 Retaining Ring Pliers 1

H 1P-1864 Retaining Ring Pliers 1

K 1P-1855 Retaining Ring Pliers 1

L 439-3940 Link Bracket 2

M FT-0947 Spring Compressor 2

N 138-7574 Link Bracket 2

P 138-7574 Link Bracket 1

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 Illustration 1 g00646497

1. Install retainer plate (2), ball bearing (1), and the dowels on bearing cage assembly (3).
Position the dowels to a depth of 16 ± 0.5 mm (0.63 ± 0.02 inch).
2. Attach bearing cage assembly (3) to Tooling (A) at locations (W) and (X).

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Illustration 2 g00646500

3. Use Tooling (B) to install retaining ring (4) on bearing cage assembly (3).

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 Illustration 3 g00646502

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Illustration 4 g00646507

5. Install sun gear (7) in clutch hub (6). Install retaining ring (5).
6. Install sun gear (7) and clutch hub (6) as an assembly on bearing cage assembly (3).
Install bolts (8).

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 Illustration 5 g00646510

7. Install friction discs (9) and clutch plates (10). Install the friction discs (9) and clutch
plates (10) in alternating order. Start with a friction disc and end with a friction disc.

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Illustration 6 g00646511

8. Install springs (11) and reaction dowels (12) on bearing cage assembly (3).

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 Illustration 7 g00646513

9. Install seal rings (13) in clutch piston (14). Lubricate the seal rings with the lubricant that
is being sealed.

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Illustration 8 g02495756

10. Install clutch piston (14) in clutch housing (16).

11. Install bearing outer race (16A) and then retaining ring (15) in clutch housing (16).

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 Illustration 9 g01020920

12. Turn over clutch housing (16). Attach Tooling (C) and a suitable lifting device to clutch
housing (16). The weight of the clutch housing (16) is approximately 36 kg (80 lb).
13. Install clutch housing (16) on the bearing cage assembly. The springs should be seated on
the bearing cage assembly (13) and the clutch piston (14) (not shown).

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Illustration 10 g00646518

14. Install friction discs (17) and clutch plate (18). Install friction discs (17) and clutch plates
(18) in alternating order. Start with a friction disc and end with a friction disc.

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 Illustration 11 g00646519

15. Install ring gear (19) on clutch housing (16). The teeth of ring gear (19) will mesh with
the teeth of friction discs (17).

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Illustration 12 g00646521

16. Install springs (20) and dowels (21) on clutch housing (16).

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 Illustration 13 g00646522

17. Install dowels (23) in clutch housing assembly (22). Install dowels (23) to a depth of 16 ±
0.5 mm (0.63 ± 0.02 inch).
18. Install plug (24) and the O-ring seal in clutch housing assembly (22).

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Illustration 14 g00646523

19. Install seal rings (25) in clutch piston (26).

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 Illustration 15 g00646524

20. Install piston (26) in clutch housing assembly (22).

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Illustration 16 g00646525

21. Turn over clutch housing (22). Install dowels (27) in clutch housing assembly (22).
Position dowels (27) to a depth of 16 ± 0.5 mm (0.63± 0.02 inch).

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 Illustration 17 g01020923

22. Attach Tooling (C) and a suitable lifting device in clutch housing assembly (22). Install
clutch housing assembly (22) on clutch housing (16). The springs should be seated on the
bearing cage assembly and the clutch piston.

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Illustration 18 g00646527

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 Illustration 19 g00646529

24. Install tube (28) in planetary carrier (32).

25. Lubricate bearing (29) with the lubricant that is being sealed. Install bearing (29) and
thrust disc (33) on each side of gear (30). Position gear (30), bearing (29), and thrust
discs (33) as an assembly in planetary carrier (32).
26. Align the hole in shaft (31) with the hole in carrier (32). Install shaft (31) in planetary
carrier (32).

NOTICE
The spring pins must be replaced with new parts during the assembly
of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier
assembly.

27. Install a new spring pin (34) in shaft (31). Spring pin (34) must be flush with the outside
diameter of planetary carrier (32). Repeat Steps 22 through 25 for the two remaining
shafts.

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 Illustration 20 g00646530

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Illustration 21 g00646531

29. Lubricate bearing (35) with the lubricant that is being sealed. Install bearing (35) in gear
(36). Position thrust disc (40) on each side of gear (36). Position gear (36), bearing (35),
and thrust discs (40) as an assembly in planetary carrier (32).
30. Align the spring pin hole in shaft (39) and the hole in planetary carrier (32). Insert shaft
(39) in planetary carrier (32).

NOTICE
The spring pins must be replaced with new parts during the assembly
of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier
assembly.
31. Install a new spring pin (42) in shaft (39). Spring pin must be flush with the outside
diameter of planetary carrier (32). Repeat Steps 26 through 28 for the two remaining
shafts.

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Illustration 22 g00646532

32. Heat bearing outer race and bearing (43) to a maximum temperature of 135 °C (275 °F).
Install the bearing outer race and bearing (43) on planetary carrier (32).

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Illustration 23 g00646533

33. Turn over planetary carrier (32). Install seal ring (44) on planetary carrier (32).
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Illustration 24 g00646535

34. Install metal seal ring (45) on ring gear (46).

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Illustration 25 g00646536

35. Turn over ring gear. Install metal seal ring (47) on ring gear (46). Install dowel (48).
Position dowel (48) to a depth of 3.68 ± .13 mm (0.14 ± 0.005 inch).

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 Illustration 26 g00646537

36. Install ring gear (46) in planetary carrier (32).

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Illustration 27 g00646538

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 Illustration 28 g00646539

38. Use Tooling (D) and a suitable press to install bearing (49) in bearing housing (50).

Note: Install bearing (49) in bearing housing (50) with notch (Y) in the downward
position.

39. Mark the location of notch (50) on bearing (49) for installation purposes.
40. Install O-ring seal (52) on bearing retainer (50).

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Illustration 29 g00646540

41. Mark the location of dowel (48) on ring gear (46) for installation purposes.

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 Illustration 30 g00646552

42. Install bearing housing (50) and bearing (49) on ring gear (46). Use marks on top of ring
gear (46) and bearing (49) to line up the notch in bearing (49) with the dowel in ring gear
(46).

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Illustration 31 g00646555

43. Use Tooling (B) to install retaining ring (53) on ring gear (46).

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 Illustration 32 g00646556

44. Install friction discs (54) and clutch plates (55). Install friction discs (54) and clutch
plates (55) in alternating order. Start with a friction disc and end with a friction disc.

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Illustration 33 g00646557

45. Install seal ring (56) on rotation housing assembly (57).

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 Illustration 34 g00646558

46. Install seal ring (58) on clutch piston (59). Lubricate seal ring (58) with the lubricant that
is being sealed.

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Illustration 35 g00646560

47. Position clutch piston (59) on rotation housing assembly (57). Do not press clutch piston
(59) in place.

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 Illustration 36 g00646561

48. Install housing (60). The teeth on housing (60) should mesh with the teeth on clutch
piston (59). Use two guide bolts to align housing (60), clutch piston (59), and rotation
housing assembly (57).
49. Install clutch piston (59) on rotation housing assembly (57).
50. Remove housing (60) and guide bolts (61).

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Illustration 37 g00646562

51. Install springs (62) on clutch piston (59).

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 Illustration 38 g00646563

52. Install seal ring (63) on balance piston (64). Lubricate seal ring (63) with the lubricant
that is being sealed.

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Illustration 39 g00646564

53. Position balance piston (64) on rotation housing assembly (57). Install bolts (65) and the
washers.

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.
54. Tighten bolts (65) evenly.

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Illustration 40 g00646565

55. Turn over rotation housing assembly (57). Install ring carrier (67) and spring pin (66) on
rotation housing assembly (57).
56. Install seal rings (68) on ring carrier (67).

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Illustration 41 g00646567

57. Position bearing (69) with the retaining ring in the down position, as shown. Use a pipe
with an inside diameter of 76.2 mm (3 inch), Tooling D, and a suitable press to install
ball bearing (69) on center shaft (70).
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Illustration 42 g00646569

58. Install center shaft (70) in the rotation housing assembly. Install retaining ring (71) on
center shaft (70).

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Illustration 43 g01020941

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 Illustration 44 g00646571

60. Install Tooling (C) on housing (60). Install housing (60) on planetary carrier (32). Align
the teeth of housing (60) with the teeth of the clutch plates. Remove Tooling (C).
61. Use two 3/8 in - 16 NC guide bolts to align the holes in rotation housing assembly (57)
with the holes in bearing retainer (50). Position rotation housing assembly (57) and shaft
(70) on housing (60). The teeth of the clutch piston should engage with the teeth of
housing (60). The bolt holes on rotation housing assembly (57) should line up with the
bolt holes of housing (60).
62. Remove retaining ring (72) from the ball bearing.

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Illustration 45 g00646572

63. Note: Do not remove the two guide bolts at this time.
64. Install bolts (74) and the washers. Tighten bolts (74) at this time.
65. Remove the two guide bolts. Install bolts (73) and the washers. Tighten bolts (73) only
after bolts (74) have been tightened.
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Illustration 46 g00646573

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Illustration 47 g00646575

67. Install Tooling (F) to center shaft (70). Attach a suitable lifting device to Tooling (F).
Secure the suitable lifting device to a hoist. The weight of the planetary carrier, the
housings, and the center shaft as an assembly is approximately 136 kg (300 lb).
68. Install the assembly. The teeth of planetary carrier (32) will mesh with the teeth of sun
gear (7) (not shown) and ring gear (18) (not shown).

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 Illustration 48 g00646577

69. Install manifold (75) on bearing (69).

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Illustration 49 g00646578

70. Use Tooling (G) to install retaining ring (72) on ball bearing (69).

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 Illustration 50 g01020942

71. Install plugs (77) and the O-ring seals in center manifold (76). Attach Tooling (C) to
center manifold (76).

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Illustration 51 g01020943

72. Attach a suitable lifting device to Tooling (C). Secure the suitable lifting device to a
hoist. Install center manifold (76). The weight of center manifold (76) is approximately
58 kg (128 lb).
73. Use two 3/8 in - 16 NC guide bolts to align manifold (75) with center manifold (76).
Install three bolts that secure manifold (75) to center manifold (76). Remove the two
guide bolts. Install the remaining two bolts that secure manifold (75) to manifold (76).

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 Illustration 52 g00646589

74. Install two of 12 bolts (78) and the washers.

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Illustration 53 g00646590

75. Install seal rings (79) and the dowel on ring carrier assembly (80).

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 Illustration 54 g00646591

76. Position ring carrier assembly (80), as shown. Install bolts (81).
77. Put a mark on the top of ring carrier assembly (80). The mark should represent the
location of the dowel on ring carrier assembly (80).

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Illustration 55 g00646592

78. Install seal ring (82) on housing (83).

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 Illustration 56 g00646594

79. Install seal ring (84) on clutch piston (85).

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Illustration 57 g00646597

80. Lubricate the seal rings on clutch piston (85) and housing (83) with the lubricant that is
being sealed.
81. Position clutch piston (85) on housing (83). Position housing (86) on housing (83) for
proper alignment. The teeth of housing (83) should engage with the teeth of clutch piston
(82). The bolt holes of housing (83) should line up with the bolt holes of housing (86).
82. Install clutch piston (85) in housing (86). Remove housing (86) and the guide bolts.

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 Illustration 58 g00646599

83. Install springs (87) in clutch piston (85).

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Illustration 59 g00646601

84. Install seal ring (90) on balance piston (89).

85. Install bearing (88) in balance piston (89). The notch (Z) in bearing (88) should be in a
downward position, as shown. Mark the top of bearing (88) for installation procedures.

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 Illustration 60 g01020944

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Illustration 61 g01020946

87. Lubricate the seal ring on balance piston (89) with the lubricant that is being sealed.
Position balance piston (89) on clutch piston (85).

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.

88. Install four of six bolts (91) and the washers. Tighten bolts (91) evenly in order to
compress the springs.
89. Install Tooling (C) and a suitable lifting device on balance piston (89). The weight of
balance piston (89), clutch piston (85), the bearing, and the housing as single unit is
approximately 45 kg (100 lb).
90. Install balance piston (89), clutch piston (85), bearing (88), and the housing as a single
unit. The notch on bearing (88) should line up with the dowel on ring carrier assembly
(80).
91. Remove Tooling (C). Install two remaining bolts (91) and the washers.

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Illustration 62 g00646608

92. Use Tooling (B) to install retaining ring (93) on ring carrier assembly (80).
93. Install seal ring (92) on ring carrier assembly (80).

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Illustration 63 g01020949
94. Install Tooling (C) in housing (86). Install housing (86) by hand. The teeth of housing
(86) should engage the teeth of clutch piston (85). The bolt holes of housing (86) should
line up with the bolt holes of housing (83) (not shown).

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Illustration 64 g00646610

95. Install metal ring seals (94) on sun gear (95).

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Illustration 65 g00646612

96. Install sun gear (95).

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 Illustration 66 g00646614

97. Install friction discs (96) and clutch plates (97). Install the friction discs (96) and clutch
plates (97) in alternating order. Start with a friction disc and end with a friction disc.

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Illustration 67 g00646616

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 Illustration 68 g00646617

99. Install orifice (104) in shaft (99).

100. Lubricate bearing (101) with the lubricant that is being sealed. Install bearing
(101) in gear (102). Position one thrust disc (98) on each side of gear (102). Position gear
(102), bearing (101), and thrust discs (98) in planetary carrier (100) as an assembly.
101. Line up the holes for the spring pin (103). One hole is in shaft assembly (99). One
hole is in planetary carrier (100). Install shaft assembly (99) in planetary carrier (100).

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Illustration 69 g00646620

NOTICE
The spring pins must be replaced with new parts during the assembly
of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier
assembly.
103. Install a new spring pin (103) in shaft assembly (99). Spring pin (103) should be
flush with the outside diameter of planetary carrier (100).

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Illustration 70 g01020952

104. Attach Tooling (C) and a suitable lifting device on planetary carrier (100). Install
planetary carrier (100). The weight of planetary carrier (100) is approximately 23 kg (50
lb).
105. Install bolts (105) and the washers.

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Illustration 71 g00646624
106. Install dowels (107) in clutch housing (106). Position dowels (107) to a depth of
16 ± 0.5 mm (0.63 ± 0.02 inch).

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Illustration 72 g00646626

107. Turn over clutch housing (106). Install dowels (108) in clutch housing (106).
Position dowels (108) to a depth of 16 ± 0.5 mm (0.63 ± 0.02 inch).

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Illustration 73 g01020956

108. Attach Tooling (C) and a suitable lifting device to clutch housing assembly (106).
Install clutch housing assembly (106). The weight of clutch housing assembly (106) is
approximately 30 kg (66 lb).
109. Install bolts (109) and the washers. Remove Tooling (C).
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Illustration 74 g00646630

110. Install ring gear (110). The teeth of ring gear (110) should mesh with the teeth of
the gears on planetary carrier (100).

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Illustration 75 g00646632

111. Install seal rings (111) on clutch piston (112).

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 Illustration 76 g00646634

112. Lubricate the seal rings on clutch piston (112) with the lubricant that is being
sealed. Install clutch piston (112) in clutch housing assembly (106).

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Illustration 77 g00646637

113. Install friction discs (113) and clutch plate (114). Install the clutch plate (114)
between the two friction discs (113).

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 Illustration 78 g00646638

114. Install dowels (115) on clutch housing assembly (106). Install springs (116) on
clutch piston (112).

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Illustration 79 g01020958

115. Install Tooling (C) and a suitable lifting device to clutch housing (117). Install
clutch housing (117) on clutch housing assembly (106). The springs should seat in clutch
housing (117) and clutch piston (112) (not shown). The weight of clutch housing (117) is
approximately 39 kg (85 lb).

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 Illustration 80 g00646640

116. Install seal rings (118) on clutch piston (119).

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Illustration 81 g00646641

117. Lubricate the seal rings on clutch piston (119) with the lubricant that is being
sealed. Install clutch piston (119) in clutch housing assembly (117).

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 Illustration 82 g00646642

118. Install O-ring seal (120) and metal seal ring (122) on sun gear (121).

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Illustration 83 g00646644

119. Install sun gear (121) on center shaft (70).

120. Use Tooling (H) to install retaining ring (122) on center shaft (70).

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 Illustration 84 g00646645

121. Install cup plugs (123) in ring gear assembly (124).

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Illustration 85 g00646647

122. Use two people to install ring gear assembly (124). The weight of ring gear
assembly (124) is approximately 35 kg (77 lb).

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 Illustration 86 g00646648

123. Install locking plates (125) between planetary carrier (100) and ring gear (124).
Install bolts (126).

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Illustration 87 g00646650

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 Illustration 88 g00646651

125. Install plug (133) in shaft assembly (131).

126. Lubricate bearings (128) with the lubricant that is being sealed. Install bearings
(128) in gear (129). Position thrust disc (127) on each side of gear (129). Position gear
(129), bearings (128), and thrust discs (127) as an assembly in planetary carrier (130).
127. The spring pin hole in shaft assembly (131) should line up with the hole in
planetary carrier (130). Install shaft assembly (131) in planetary carrier (130).

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Illustration 89 g00646652

NOTICE
The spring pins must be replaced with new parts during the assembly
of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier
assembly.
129. Install new spring pin (132) until the end of spring pin is flush with planetary
carrier (130).

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Illustration 90 g01020960

130. Install Tooling (C) and a suitable lifting device on planetary carrier (130). Install
planetary carrier (130). The gears on planetary carrier (130) should mesh with the teeth
on ring gear (124). The weight of planetary carrier (130) is approximately 55 kg (120 lb).

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Illustration 91 g00646654
131. Position bearing (133) on the center shaft. The words on bearing (133) should
face downward. Install bearing (133). Use a 1 1/2 inch socket head to install bearing
(133).

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Illustration 92 g03803892

132. Note: Callout (134) is missing from the photograph due to an engineering
correction.
133. Use Tooling (K) to install retaining ring (135) on center shaft (70).

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Illustration 93 g00646656

134. Install drive adapter (136). Install bolts (137).

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Illustration 94 g00646658

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Illustration 95 g00646659

136. Install lockring (138) on sun gear (139).

137. Position six 1/8 in x 1 in pins (141) between lockring (138) and coupler (140).
Pins (141) will allow coupler (140) to slide over lockring (138). The sun gear (139) and
coupler (140) will be connected as an assembly by lockring (138).

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 Illustration 96 g00646661

138. Install sun gear (139) and coupler (140) as an assembly.

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Illustration 97 g00646663

139. Use a screwdriver to install retaining ring (142). Retaining ring (142) goes
between coupler (140) and ring gear (124) (not shown).

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 Illustration 98 g00646664

140. Use Tooling (G) to install retaining ring (143) on planetary carrier (130).

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Illustration 99 g00646667

141. Lubricate bearings (145) with the lubricant that is being sealed. Install bearings
(145) in gear (146). Position thrust disc (144) on each side of gear (146). Position gear
(146), bearings (145), and thrust discs (144) as an assembly in planetary carrier (147).
142. The spring pin hole in shaft (148) should line up with the hole in planetary carrier
(147). Install shaft (148).

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 Illustration 100 g00646671

NOTICE
The spring pins must be replaced with new parts during the assembly
of the carrier assembly.

Failure to use new spring pins could result in damage to the carrier
assembly.

144. Install new spring pin (149) in shaft (148). Install spring pin (149) until the end of
the spring pin is flush with planetary carrier (147).

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Illustration 101 g00646672

145. Install O-ring seal (150) and metal seal rings (151) on manifold (152).
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Illustration 102 g00646675

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Illustration 103 g01020961

147. Install manifold (152) on planetary carrier (147). Install seven of the nine bolts
(153) and the washers.
148. Attach Tooling (L) and a suitable lifting device to planetary carrier (147) and
manifold (152).
149. Install planetary carrier (147) and manifold (152) as an assembly. The weight of
planetary carrier (147) and manifold (152) as single unit is approximately 57 kg (125 lb).
150. Remove Tooling (L). Install remaining bolts (153) and the washers.

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 Illustration 104 g00646679

151. Install friction discs (155) and clutch plates (154). Install friction discs (155) and
clutch plates (154) in alternating order. Start with a friction disc and end with a friction
disc.
152. Install springs (156) on clutch piston (119).

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Illustration 105 g00646681

153. Install dowels (158) in plate assembly (157). Position dowels (158) to a depth of
12.5 ± 0.5 mm (0.5 ± 0.02 inch).
154. Install 24 dampers (159) in the bolt holes of plate assembly (157).

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 Illustration 106 g00646683

155. Turn over plate assembly (157). Install dowels (160). Position dowels (160) to a
depth of 12.5 ± 0.5 mm (0.5 ± 0.02 inch).

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Illustration 107 g00670958

156. Use two people to install plate assembly (157). The weight of plate assembly is
approximately 30 kg (66 lb). The springs should seat in plate assembly (157) and clutch
piston (119) (not shown).

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 Illustration 108 g00646685

157. Install ring gear (161).

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Illustration 109 g00646690

158. Install reaction dowels (162).

159. Install friction discs (164) and clutch plates (165). Install friction discs (164) and
clutch plates (165) in alternating order. Start with a friction disc and end with a friction
disc.
160. Install springs (163).

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 Illustration 110 g00646692

161. Install seal rings (166) on clutch piston (167).

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Illustration 111 g00646694

162. Lubricate the seal rings on clutch piston (167) with the lubricant that is being
sealed. Install clutch piston (167) in clutch housing assembly (168).
163. Attach Tooling (P) (not shown) and a suitable lifting device to clutch housing
assembly (168) at position (V). Turn over clutch housing assembly (168). The weight of
the clutch housing assembly is approximately 100 kg (220 lb).

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 Illustration 112 g00646696

164. Attach Tooling (M) in order to hold the clutch piston to clutch housing assembly
(168). Attach Tooling (N) and a suitable lifting device to clutch housing assembly (168).
Install clutch housing assembly (168) on plate assembly (157). Springs (163) (not shown)
should seat in plate assembly (157) and clutch piston (167) (not shown).

Note: Do not remove Tooling (N) at this time.

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Illustration 113 g00646699

165. Install ball (170) and plug (169) in clutch housing assembly (168).

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 Illustration 114 g00646700

166. Install bolts (171) and the washers.

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Illustration 115 g00646701

167. Use Tooling (N) (not shown) to secure the transmission planetary. Remove the
two bolts that hold the transmission planetary to Tooling (A) at position (W) and (X).
168. Install the remaining ten bolts (78) and the washers.

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 Illustration 116 g00646702

169. Install the transmission planetary in the transmission case. Remove forcing screws
(173). The weight of the transmission is approximately 1000 kg (2200 lb).
170. Install bolts (172) and the washers.

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Illustration 117 g00646703

171. Remove Tooling (N) and the suitable lifting device from the transmission. Attach
the transmission case (174) to Tooling (A). Position transmission case (174) on a flat
surface horizontally. The weight of the transmission planetary and transmission case
(174) is approximately 1100 kg (2420 lb).

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 Illustration 118 g00646705

172. Use Tooling (D) to install sleeve bearing (175) in input shaft (177).
173. Install O-ring seal (176) on input shaft (177).

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Illustration 119 g00646706

174. Install input shaft (177) in the transmission planetary.

175. Install O-ring seal (178) on the transmission case.

End By:

a. Install the transmission hydraulic control. Refer to Disassembly and Assembly,

"Transmission Hydraulic Control - Install".
b. Connect the transmission to the transfer gears. Refer to Disassembly and Assembly,
"Transmission and Transfer Gears - Connect".
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