992D Torq R&I

992D Wheel Loader 7MJ00001-UP (MACHINE) POWERED BY 3412 Engine(SEBP20...
Page 1 of 22
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Product: WHEEL LOADER

Model: 992D WHEEL LOADER 7MJ
Configuration: 992D Wheel Loader 7MJ00001-UP (MACHINE) POWERED BY 3412 Engine
Disassembly and Assembly

992D WHEEL LOADER POWER TRAIN
Media Number -SENR5709-04 Publication Date -01/08/2004 Date Updated -28/04/2011
SENR57090014
Torque Converter
SMCS - 3100-010; 3100-016
Remove & Install Torque Converter

Start By:
a. remove stub shaft group
b. remove transmission oil pump
c. remove torque converter sequence and pressure control valve
d. remove pressure relief valve for torque converter outlet
1. Disconnect the oil drain line from the bottom of the torque converter and then drain the torque
converter.
2. Disconnect hydraulic hose (1) from the torque converter. Put a cap or cover on hose.
https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisw... 2018/06/22
992D Wheel Loader 7MJ00001-UP (MACHINE) POWERED BY 3412 Engine(SEBP20... Page 2 of 22
3. Disconnect hose and block (2) from the torque converter.
4. Install two 1/2 " - 13 NC forged eyebolts on the torque converter, then fasten a hoist. Remove the
bolts that hold torque converter (3) to the flywheel housing. Remove the torque converter. The weight
of the torque converter is 242 kg (538 lb).
NOTE: The following steps are to install the torque converter.
5. Fasten a hoist to torque converter (3) and put it in position on the flywheel housing. Install the bolts
that hold the torque converter.
6. Connect hose and block (2) to the torque converter.
7. Remove the cap or cover from hydraulic hose (1), then connect the hose to the torque converter.
8. Connect oil drain line to bottom of torque converter, then fill torque converter with oil to the
correct level. See LUBRICATION AND MAINTENANCE GUIDE.
End By:
a. install pressure relief valve for torque converter outlet
b. install torque converter sequence and pressure control valve
c. install transmission oil pump
d. install stub shaft group
Disassemble Torque Converter
Start By:
a. remove torque converter
1. Put the torque converter on wooden blocks for support.
2. Remove bolt (3), washer (2) and yoke (1) from the torque converter.
3. Remove bolts (4) from the torque converter case.
4. Install one 1/2 " - 13 NC forged eyebolt (5) and one 3/8 " - 16 NC forged eyebolt (6) in the torque
converter case. Fasten a hoist to the eyebolts and use two 1/2 " - 13 NC forcing screws (7) to remove
the torque converter case. The weight of the case is 75 kg (165 lb).
5. Remove two O-ring seals (8) from the inner carrier. Remove bolts (9) that hold the outer carrier to
the inner carrier.
6. Install two 3/8 " - 16 NC forcing screws (10) in the outer carrier. Remove the outer carrier from the
inner carrier.
7. Remove the shaft, bearing and outer carrier from the torque converter. Remove the two O-ring
seals from behind the outer carrier.
8. Remove shaft (11) and the bearing from the outer carrier with a press.
9. Remove the lip-type seal from the outer carrier with tooling (A).
10. Remove sleeve (12) and ring (13) from the shaft.
11. Remove bearing (14) and seal carrier from shaft with tooling (B).
12. Remove bolts (15) that hold the centrifugal valve in place. Remove centrifugal valve (16) from the
torque converter housing.
13. Remove plug (21), spacers (20), spring (19), slug (18) and valve spool (17) from the valve body.
14. Remove spiral snap ring (22) from the inner carrier.
NOTE: Current models, beginning with Serial No. 75T2615 will have a different retaining
configuration. These models will have retaining ring and a retaining plate and a second retaining ring
as shown in Illustration C38031P1. In this case remove ring (Y), plate (X) and ring (Z).
15. Remove inner carrier (23) from the torque converter cover.
16. Remove two seal rings (24) from the inner carrier.
NOTICE
Do not remove the seal carrier if it is not necessary. The tooling can
cause damage to the seal carrier.
17. Remove roll pin (25) from the seal carrier with a hammer and punch.
NOTICE
Be careful not to damage the seal carrier when the roll pin is removed.
18. Remove the seal carrier from the inner carrier with tooling (C).
19. Remove bolts (26) from the torque converter housing assembly.
20. Install two 3/8 " - 16 NC forcing screws in the housing assembly and make enough separation
between the two housings to install two 3/8 " - 16 NC forged eyebolts with nuts. Fasten a hoist to the
housing (27) and remove it. The weight of the housing is 68 kg (150 lb).
21. Remove bolts (28) that hold hub (29) to the housing assembly.
22. Use the wooden handle of a hammer to gently tap the hub from the three dowels.
23. Turn the housing assembly over and then use three 1/2 " - 13 NC forcing screws (31) to make a
separation between impeller (30) and the housing assembly.
24. Remove bolts (32), then remove disc assembly (33).
25. Remove inner impeller (34) from the housing assembly.
26. Remove teflon ring (35) from the inner impeller.
992D Wheel Loader 7MJ00001-UP (MACHINE) POWERED BY 3412 Engine(SEBP... Page 10 of 22
27. Remove piston (36) from the housing assembly with a pry bar.
28. Remove teflon seal (37) from the piston.
29. Remove teflon seal (38) from the housing assembly.
30. Turn the housing assembly over and remove bearing (39) with tooling (D).
31. Remove the stator and carrier (40) as a unit from the turbine.
32. Remove retainer (41), race (42), bearing (44) and plate (43) from the stator carrier.
33. Turn the stator and carrier over and remove snap ring (45), plate (46) and the snap ring.
34. Heat the stator and carrier to a temperature of 149°C (300°F) for five minutes only. Remove the
stator from carrier (47) with a press while it is hot. Make sure to hold the carrier so it does not drop
and get damaged.
35. Remove bearing (48) from the stator carrier with tooling (E).
36. Remove bearing (49), race and retainer from the turbine.
37. Remove turbine (50) and hub from the housing. Turn the turbine and hub over and pull the hub on
a block.
38. Remove race (51) from the hub.
NOTE: Perform Steps 39, 40 and 41 if the turbine or turbine hub needs replacement.
39. Remove bolts (52) that hold the turbine and hub together.
40. Remove turbine (50) from the hub.
41. Remove pin (53) from the hub with a hammer and punch.
42. Remove bearing (54), race and retainer (55) from inside of the housing.
43. Turn the housing over and remove the bolts from spider (56). Install three 1/2 " - 13 NC forcing
screws (57) and remove spider from the housing.
44. Remove bearing (58) from the housing with tooling (E).
Assemble Torque Converter
NOTE: Two torque specifications are given in the following steps, old and current. Old is for Part
No. 6T6780 (Serial No. 49Z to 49Z802) and current is for Part No. 9W1563/6Y5800 (Serial No.
49Z803 & UP and 7MJ1 & UP).
1. Make sure all bearings are clean. Put clean transmission oil on all bearings before assembly.
2. Lower the temperature of the bearing and install the bearing in the housing with tooling (A). The
other edge of bearing must be even with the face of the housing when installed.
3. Install spider (1) on housing. Install bolts (2) and tighten bolts to a torque of 110 ± 5 N·m (80 ± 4
lb ft) for older models and 120 ± 15 N·m (90 ± 11 lb ft) for current models.
4. Turn the housing over and install retainer (5), race (4) and bearing (3) in the housing. The round
edge of race (4) must be installed toward the retainer.
5. Put the hub on a block and push pin (6) into the hub.
6. Install turbine (7) on the hub. Tighten bolts (8) in the hub to a torque of 110 ± 5 N·m (80 ± 4 lb ft)
for older models and 120 ± 15 N·m (90 ± 11 lb ft) for current models.
7. Put a small amount of 1P808 General Purpose Lubricant on the race (9) to hold it in place on the
hub during assembly. The side of the race with the round edge must be installed toward the hub.
8. Install the turbine and hub in the housing. Make sure race (9) does not move during installation.
9. Install retainer (12), race (11) and bearing (10) in the turbine. Make sure the side of the race with
the round edge is toward the retainer and notch is over pin.
10. Lower the temperature of the bearing. Install bearing in the stator carrier with tooling (C). The
outer edge of bearing must be even with outer edge of carrier when installed.
11. Install inner snap ring (14) in the stator. Make sure snap ring (14) is fully seated in the groove.
12. Heat the stator to 149°C (300°F). Install the stator on the carrier with the wide spline (13) in
alignment with groove (15) in the carrier. Make sure the carrier is against snap ring (14) when
installed.
13. Install ring (17) and snap ring (16) in the carrier. Make sure the snap ring is fully seated in the
groove.
14. Turn the carrier and stator over and install ring (21), bearing (20), race (19) and retainer (18).
Make sure the side of the race with the round edge is toward the retainer.
15. Install the carrier and stator in the turbine.
16. Lower the temperature of bearing (22) and install in clutch housing with tooling (C). The outer
edge of the bearing must be even with the bottom of the chamfer in the clutch housing when installed.
17. Install teflon seal (25) on housing assembly and teflon seal (24) on piston (23). Install piston (23)
on the three dowels in the housing assembly.
18. Install ring (27) on inner impeller (26). Install the inner impeller in the outer impeller.
19. Install disc assembly (28) on the inner impeller. Install the bolts that hold the disc assembly and
tighten them to a torque of 25 ± 1 N·m (20 ± 1 lb ft) for older models and 30 ± 5 N·m (22 ± 4 lb ft)
for current models.
20. Put the three holes in disc assembly and inner impeller in alignment with the three dowels in the
housing assembly. Install the disc assembly and inner impeller on these three dowels.
21. Put the housing assembly on wooden blocks. Install hub (29) on the three dowels. Install two of
the bolts that hold the hub, then turn the housing over.
22. Install the remainder of bolts (30) and tighten to a torque of 115 ± 7 N·m (85 ± 5 lb ft) for older
models and 120 ± 15 N·m (90 ± 11 lb ft) for current models.
23. Install two 3/8 " - 16 NC forged eyebolts and two nuts on the housing assembly. Fasten a hoist to
the housing assembly and put it in position over housing (32). Install two 3/8 " - 16 NC forcing
screws (31) to hold up the housing assembly while the nuts from the eyebolts are removed. Lower
housing assembly on to housing (32). Remove hoist, eyebolts and forcing screws. Install bolts and
tighten them to a torque of 50 ± 3 N·m (37 ± 2 lb ft) for older models and 50 ± 7 N·m (37 ± 5 lb ft)
for current models.
24. Heat seal carrier (33) to 149°C (300°F). Install the seal carrier on carrier with the notch in
alignment with the pin hole in the carrier. Install pin (34) to hold the seal carrier so it will not turn.
25. Install two seal rings (35) on seal carrier. Install carrier into the housing assembly and install the
spiral retainer ring that holds the carrier in place.
26. Install valve spool (36), slug (37), spring (38), spacers (39) and plug (40) in the centrifugal valve
body. Tighten plug (40) to a torque of 25 ± 4 N·m (20 ± 3 lb ft).
27. Install centrifugal valve (41) on the clutch housing. Tighten the bolts that hold the valve in place
to a torque of 25 ± 1 N·m (20 ± 1 lb ft) for older models and 30 ± 5 N·m (22 ± 4 lb ft) for current
models.
28. Heat seal carrier (43) and bearing (42) to 149°C (300°F) to install it on the shaft.
29. Install the seal in outer carrier (44) with tooling (C). The lip of the seal must be toward the inside
when installed. Put clean transmission oil on the lip of the seal.
30. Install seal ring and sleeve (45) on the shaft. Put shaft in position in a press as shown. Push the
outer carrier in place on the bearing with tooling (D).
31. Install the two O-ring seals on the outer carrier. Make sure the O-ring seal for the oil passage does
not move during assembly.
32. Install the shaft and carrier in the housing. Make sure the oil passages in the two carriers are in
alignment. Install the bolts that hold the two carriers together.
33. Install two O-ring seals (47) on stator support carrier (46). Put a small amount of 1P808 General
Purpose Lubricant on the outer O-ring seal to hold it in place at assembly.
34. Install two 1/2 " - 13 NC guide bolts (51) in the housing assembly. Install one 1/2 " - 13 NC
forged eyebolt (48) and one 3/8 " - 16 NC forged eyebolt (49) in torque converter cover (50). Fasten a
hoist to the torque converter cover and install it on the housing assembly. Remove the guide bolts,
eyebolts and hoist.
35. Install torque converter cover bolts (52). Install yoke (53), washer and bolt. Tighten the bolt to a
torque of 115 ± 7 N·m (85 ± 5 lb ft) for older models and 120 ± 15 N·m (90 ± 11 lb ft) for current
models.
End By:
a. install torque converter
Copyright 1993 - 2018 Caterpillar Inc. Fri Jun 22 08:37:11 MDT 2018
All Rights Reserved. sunhills
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992D Wheel Loader 7MJ00001-UP (MACHINE) POWERED BY 3412 Engine(SEBP20...

Product: WHEEL LOADER

Disassembly and Assembly

Remove & Install Torque Converter

a. remove stub shaft group

b. remove transmission oil pump

c. remove torque converter sequence and pressure control valve

d. remove pressure relief valve for torque converter outlet

3. Disconnect hose and block (2) from the torque converter.

NOTE: The following steps are to install the torque converter.

6. Connect hose and block (2) to the torque converter.

a. install pressure relief valve for torque converter outlet

b. install torque converter sequence and pressure control valve

c. install transmission oil pump

d. install stub shaft group

Disassemble Torque Converter

a. remove torque converter

1. Put the torque converter on wooden blocks for support.

3. Remove bolts (4) from the torque converter case.

24. Remove bolts (32), then remove disc assembly (33).

25. Remove inner impeller (34) from the housing assembly.

26. Remove teflon ring (35) from the inner impeller.

28. Remove teflon seal (37) from the piston.

29. Remove teflon seal (38) from the housing assembly.

38. Remove race (51) from the hub.

40. Remove turbine (50) from the hub.

Assemble Torque Converter

15. Install the carrier and stator in the turbine.

a. install torque converter

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