Caterpillar Cat 938F Wheel Loader (Prefix 7SN) Service Repair Manual (7SN00001 and up)

Service Repair Manual
Models
938F Wheel Loader

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Product: WHEEL LOADER
Model: 938F WHEEL LOADER 7SN
Configuration: 938F Wheel Loader 7SN00001-UP (MACHINE) POWERED BY 3116 Engine
Disassembly and Assembly
938F WHEEL LOADER POWER TRAIN
Media Number -SENR6706-04 Publication Date -01/08/2004 Date Updated -26/10/2004
SENR67060026
Torque Converter
SMCS - 3101-015; 3101-016; 3150-015; 3150-016
Disassemble Torque Converter
Start By:
a. remove transmission and torque converter
b. separation of transmission from torque converter
1. Install Tool (A) as shown.
2. Remove six bolts (1).
3. Lift transmission cover (2) straight up and off the torque converter. The weight of the
transmission cover is 150 kg (330 lb).
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5. Remove eighteen bolts (2) and washers.
6. Install two forcing screws as shown.
7. Separate driver gear (3) and stator carrier (4) from rotating housing (5).
8. Remove six socket head bolts (6).
9. Remove two clamp plates (7).
10. Use Tool (B) to remove retaining ring (8).
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11. Carefully tap stator carrier (4) from converter impeller (9).
12. Check seal ring (11) for damage or wear and replace if necessary.
13. Remove twelve bolts (12).
14. Remove drive gear (3) from converter impeller (9).
15. Use a suitable press to remove ball bearing from the converter impeller (9).
16. Use Tool (B) to remove retaining ring (14).
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17. Lift converter turbine (15) from rotating housing (5).
18. Remove rear bearing lock (16).
19. Remove end cover (17).
20. Turn the rotating housing over and use a soft hammer to tap splined hub and ball bearing (18)
out of the housing.
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21. Use Tool (B) to remove snap ring (19) from splined hub (18).
22. If necessary, remove ball bearing from splined hub.
23. Check the condition of locating ring (21) on the outside diameter of ball bearing (20) and
replace if necessary.
24. Check oil dam or "D" ring (22) for damage or wear and replace if necessary.
Assemble Torque Converter
1. Check oil dam or "D" ring (22) for damage or wear and replace if necessary.
2. Use Tool (B) to install snap ring (19) to splined hub (18).
3. If removed, install bearing (20) to splined hub (18).
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4. Check the condition of locating ring (21) on the outside diameter of ball bearing (20) and
5. Turn the rotating housing over and assemble splined hub and bearing (18) to the housing.
6. Install end cover (17).
7. Install rear bearing lock (16).
8. Assemble converter turbine (15) to rotating housing (5).
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9. Use Tool (B) to install retaining ring (14).
10. Heat bearing (13) to 135°C (275°F) and assemble to impeller (9).
11. Install drive gear (3) to impeller (9).
12. Install twelve bolts (12) and tighten to the torque of 30 ± 5 N·m (22 ± 4 lb ft).
13. Check seal ring (11) for damage or wear and replace if necessary.
14. If removed, install six spring pins (10).
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15. Carefully install stator carrier (4) to impeller (9).
16. Install two clamp plates (7).
17. Use Tool (B) to install retaining ring (8).
18. Install six socket head bolts (6) and tighten to the torque of 30 ± 5 N·m (22 ± 4 lb ft).
19. Assemble drive gear (3) and stator carrier (4) to rotating housing (5).
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21. Install eighteen bolts (2) and washers and tighten to the torque of 30 ± 5 N·m (22 ± 4 lb ft).
23. Use M10 Guide Bolts when lowering the transmission cover (2) straight down on the torque
converter. The weight of the transmission cover is 150 kg (330 lb).
24. Install six bolts (1) tighten to the torque of 55 ± 10 N·m (40 ± 7 lb ft).
End By:
a. connection of transmission to torque converter
a. install transmission and torque converter
Disassemble Transmission
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Start By:
a. remove transmission
b. disassemble and assemble torque converter
c. disassemble transmission pump
1. Thoroughly clean the outside of the transmission (1) prior to disassembly.
2. Drain the transmission fluid into a suitable container.
3. Mark all parts and components for assembly purposes.
4. Remove bolt (2), retainer (3) and yoke (4).
5. Remove bolts (5) and retainer (6) (not shown). Check the O-ring seal (7) (not shown) behind
retainer (6) for damage or wear and replace if necessary. Remove brake drum (8).
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6. Remove four bolts (9). Remove tube assembly (10).
7. Check O-ring seal (11) (not shown) on each end of tube assembly for damage or wear and
8. Install Tool (A), chain and a suitable lifting device to shaft assembly (13) (forward shaft).
NOTE: Hold shaft assembly (12) away from shaft assembly (13) for clearance.
9. Slowly and carefully lift shaft assembly (13) straight up and out of case assembly (14). The
weight of the shaft assembly (13) is 41 kg (90 lb).
10. Install Tool (A), chain and a suitable lifting device to shaft assembly (15) (reverse shaft).
NOTE: Hold shaft assembly (12) away from shaft assembly (15) for clearance.
11. Slowly and carefully lift shaft assembly (15) straight up and out of case assembly (14). The
12. Remove input shaft (12).
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13. Install Tool (A), chain and a suitable lifting device to shaft assembly (16) (speed shaft).
14. Slowly and carefully, lift shaft assembly (16) straight up and out of case assembly (14). The
NOTE: There is a thrust disc that can fall off the bottom of the speed shaft upon removal. Take
care not to lose the thrust disc.
15. Install Tooling (B) (suitable puller group) and remove bearing (17) from output shaft (18).
16. Position shaft assembly (16) (speed shaft) on Tool (C).
NOTE: Use two flat plates marked (X) for added stability.
17. Use Tool (D) to remove retaining ring (19) and remove thrust disc (20).
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18. Remove gear (21).
19. Remove retaining ring (22) with Tool (D).
20. Separate hub assembly (23) from gear (21). If necessary, remove sleeve bearing (24).
21. Remove thrust disc (25) and retainer (26).
22. Use Tool (D) to remove retaining ring (27).
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23. Use Tool (E) and a suitable air supply to determine wear on the clutch plates and friction discs.
24. Nozzle used in step above.
25. Use a screwdriver to remove retaining ring (28).
26. Remove one end plate (29), clutch plates (31) and disc assembly (30).
27. Components in exploded view upon removal.
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28. Position the shaft assembly with retaining ring (32) as shown.
29. Install Tool (F), (I) and (J) to compress the wave spring (not shown).
30. Use Tool (D) to remove retaining ring (32). Release the pressure on the wave spring and
remove Tool (F).
31. Remove balance seal assembly (33).
32. Remove wave spring (34).
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Typical Example
33. Remove piston (35).
34. Remove balance seal assembly (33), wave spring (34) and piston seal assembly (35).
35. Use an eyebolt and a suitable lifting device to reposition the shaft assembly 180°.
36. Remove four seal rings (36).
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37. Remove thrust disc (37).
NOTE: This thrust disc may fall off when the shaft is removed from the case.
38. Use Tool (D) to remove retaining ring (38)
39. Remove gear (39).
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41. Remove gear and hub assembly (41).
42. Use Tool (G) to remove retaining ring (42).
43. Separate hub assembly (43) from gear (41).
44. If necessary, remove sleeve bearing (44). When installing sleeve bearing (44), press to a depth
of 10 mm (.4 in) from hub face.
45. Remove thrust disc (45) and ring retainer (46).
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46. Use Tool (E) and a suitable air nozzle to measure the travel of the clutch pack.
47. Use a screw driver to remove retaining ring (47).
48. Remove one end plate (48), clutch plates (49) and friction discs (50).
49. End plate (48), clutch plates (49) and friction discs (50) upon removal.
50. Use Tool (G) to remove snap ring (51).
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51. Position the shaft assembly so snap ring (52) lines up with the opening on Tool (H).
52. Install Tool (H), (I) and (J) to compress the wave spring (not shown). Use Tool (D) to remove
snap ring (52) and remove Tool (H).
53. Remove balance piston (53).
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55. Remove piston (55).
56. Exploded view of balance piston (53), wave spring (54) and piston (55) upon removal.
57. Check lip seals (56) on piston (55) for damage or wear and replace if necessary.
NOTE: Seal lip must face toward the top of piston (55) as shown.
58. Check lip seal (57) on balance piston (53) for damage or wear and replace if necessary.
NOTE: Seal lip must face toward the tip of balance piston (53) as shown.
59. Shaft assembly (16) completely disassembled.
NOTE: There are three plugs on the end of the shaft assembly.
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60. Position reverse and second shaft assembly (58) on Tool (C) as shown. Use flat plates marked
(X) for stability.
61. Use Tool (D) to remove retaining ring (59) and remove thrust disc (60).
62. Remove gear and hub assembly (61).
63. Use Tool (G) to remove retaining ring (62).
64. Separate hub (63) from gear (61). If necessary, remove sleeve bearing (64).
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65. Remove thrust disc (65) and retainer (66).
66. Use Tool (D) to remove retaining ring (67).
67. Use Tool (E) and a suitable air nozzle to check travel of the clutch plates.
68. Use a screw driver to remove retaining ring (68).
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69. Remove one end plate (61), clutch plates (62) and friction discs (63).
70. End plate (61), clutch plates (62) and friction discs (63).
71. Position the shaft assembly with retaining ring (64) in line with the opening in Tool (F).
72. Install Tool (F), (I) and (J) to compress the wave spring (not shown) and use Tool (D) to
remove retaining ring (64). Remove Tool (F).
73. Remove balance seal assembly (65).
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Typical Example
75. Remove piston seal assembly (67).
76. Balance seal (65), wave spring (66) and piston seal (67) upon removal. Check the lip seals on
the balance and piston seals for damage or wear and replace if necessary.
77. Reposition the shaft assembly with opposite end up, as shown. Remove three seal rings (68),
use Tool (D) to remove retaining ring (69).
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79. Remove washer (71) and gear (72).
80. Remove spacer assembly (73).
81. Remove thrust disc (74), gear and hub assembly (75).
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Caterpillar Cat 938F Wheel Loader (Prefix 7SN) Service Repair Manual (7SN00001 and up)

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