This document provides disassembly and assembly instructions for a 980K wheel loader torque converter. It details 46 steps to disassemble components such as the housing, gears, bearings, seals and describes 39 steps for assembly, including installing various parts back onto the impeller and shaft assembly using specific tools. The document includes illustrations and lists required tools for each procedure.
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1. Product: WHEEL LOADER
Model: 980K WHEEL LOADER GTZ
Configuration: 980K Wheel Loader GTZ00001-UP (MACHINE) POWERED BY C13 Engine
Disassembly and Assembly
980K Wheel Loader Power Train
Media Number -KENR6447-03 Publication Date -01/08/2012 Date Updated -21/08/2012
i06838048
Torque Converter - Disassemble - Lock Up Clutch With
Freewheel Stator
SMCS - 3101-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3938 Link Bracket 3
B
8B-7548 Push-Puller 1
8B-7550 Leg 2
8H-0684 Ratchet Wrench 1
8B-7560 Step Plate 1
8H-0663 Bearing Puller Attachment 1
C
8B-7548 Push-Puller 1
8H-0684 Ratchet Wrench 1
8B-7549 Leg 2
5P-4808 Cap 2
8B-7554 Bearing Cup Puller Attachment 1
D
5F-7343 Bearing Puller Attachment 1
1P-0520 Driver Group 1
E 1P-0510 Driver Group 1
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2. F 6L-7283 Forcing Bolt
3/8 - 16 by 3 in
7
G 417-1324 Adjust Stand 1
Start By:
a. Separate the torque converter from the transmission and from the output transfer gears.
Illustration 1 g02712129
1. Use Tooling (A) and a suitable lifting device to position the torque converter onto Tooling
(G) and suitable blocking. The weight of the torque converter is approximately 260 kg
(573 lb). Support the torque converter, as shown.
2. Remove bolts (1).
Illustration 2 g02730506
3. Remove relief valve assembly (2A).
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3. Illustration 3 g02711758
4. Use Tooling (F) to loosen housing assembly (2) from the torque converter.
5. Use the suitable lifting device and Tooling (A) to remove torque converter housing
assembly (2). The weight of torque converter housing assembly (2) is approximately 144 kg
(317 lb).
Illustration 4 g00871317
6. Remove O-ring seal (3) from torque converter housing assembly (2).
Illustration 5 g00871318
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4. 7. Remove bolts (4) from pump adapter (5) and torque converter housing assembly (2).
Illustration 6 g00871264
8. Use Tooling (F) to remove pump adapter (5) from torque converter housing assembly (2).
Illustration 7 g00871319
9. Use Tooling (B) to remove bearing cup (6). Remove bearing cup (6), O-ring seal (8), and
shims (7) from pump adapter (5). See illustration 14 for Tooling (C).
Illustration 8 g00871326
10. Remove pump drive gear (9) from torque converter housing assembly (2).
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5. Illustration 9 g00871451
11. Use Tooling (C) to remove bearing cones (10) from each side of pump drive gear (9).
Remove bearing cones (10).
Illustration 10 g00871333
12. Use Tooling (C) to remove bearing cup (11) from torque converter housing assembly (2).
See illustration 14 for Tooling (C).
Illustration 11 g01112900
13. Remove bolt (12) and the washer from torque converter housing assembly (2).
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6. 14. Use Tooling (F) to push shaft assembly (14) out of torque converter housing assembly (2).
15. Remove idler gear (13) from torque converter housing assembly (2).
Illustration 12 g01112903
16. Remove O-ring seal (15) from shaft assembly (14).
Illustration 13 g00871365
17. Remove bearing cone (16), bearing cone spacer (17), and bearing cone (18) from idler gear
(13).
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7. Illustration 14 g00871366
18. Use Tooling (C) to remove bearing cup (19) from idler gear (13). Remove bearing cup (19).
Illustration 15 g00871367
19. Remove bearing cup spacer (20) from idler gear (13).
Illustration 16 g00871368
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8. 20. Remove retaining ring (21) from idler gear (13).
Illustration 17 g00871369
21. Use Tooling (C) to remove bearing cup (22) from idler gear (13). Remove bearing cup (22).
Illustration 18 g00871370
22. Remove studs (23) from torque converter housing assembly (2).
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9. Illustration 19 g02729366
23. Remove bolts (24) and gear (25).
Illustration 20 g02735357
24. Use the driver group from Tooling (D) and a suitable press to remove race (25A) from gear
(25).
Illustration 21 g02730012
25. Use a suitable lifting device to reposition the torque converter, as shown. The weight of the
torque converter is approximately 122 kg (269 lb). Remove bolts (26).
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10. Illustration 22 g02730687
26. Use Tooling (F) to separate housing (27) from the torque converter.
Illustration 23 g02730689
27. Use two people to remove housing (27). The weight of housing (27) is approximately 26 kg
(57 lb). Remove housing (27), piston (28), and plate (30). Remove seals (29) from piston
(28).
Illustration 24 g02731059
28. Remove bushing (31) from housing (27).
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11. Illustration 25 g02731623
29. Remove plate (32), disk (33), races (34), and bearing (35).
Note: Note the orientation of the bearing and races for assembly purposes.
Illustration 26 g02731644
30. Remove bolts (36), coupling assembly (37), and plate (38).
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12. Illustration 27 g02731651
31. Use suitable blocking to support the bottom of shaft assembly (39). Remove retaining ring
(40) and plate (41). Shaft assembly (39) can be lowered to the work bench.
Illustration 28 g02731711
Illustration 29 g02732048
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13. 32. Install two of bolts (36) and remove turbine (42).
33. Remove bolts (36) and remove hub (43) from turbine (42).
Illustration 30 g02731732
Illustration 31 g02731802
34. Remove race (44) and bearing (45).
Note: Note the orientation of the race and bearing for assembly purposes.
35. Remove stator assembly (46).
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14. Illustration 32 g02731806
36. Remove retaining ring (47), plate (48), freewheel springs (49), freewheel rollers (50), and
freewheel cam (51). Remove plate (52) and retaining ring (53) (not shown) from stator (46).
Illustration 33 g02732255
37. Attach Tooling (A) and a suitable lifting device to impeller (54). The weightof impeller (54)
is approximately 27 kg (60 lb).
38. Remove impeller (54) from shaft assembly (39).
Illustration 34 g02735333
39. Position impeller (54) onto suitable blocking, as shown.
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15. Illustration 35 g02734776
40. Remove retaining ring (56) and hub (55).
Illustration 36 g02735372
41. Remove seal ring (56).
Illustration 37 g02734816
42. Use Tooling (D) and a suitable press to remove bearing (57).
Illustration 38 g02735374
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16. 43. Remove retaining ring (59) and carrier assembly (58) from impeller (54).
Illustration 39 g02735380
44. Remove bearing (60).
Note: Note the orientation of the bearing (60) for assembly purposes.
Illustration 40 g02735387
45. Remove bolts (61), hub (62), and adapter (63) from impeller (54).
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18. Product: WHEEL LOADER
Model: 980K WHEEL LOADER GTZ
Configuration: 980K Wheel Loader GTZ00001-UP (MACHINE) POWERED BY C13 Engine
Disassembly and Assembly
980K Wheel Loader Power Train
Media Number -KENR6447-03 Publication Date -01/08/2012 Date Updated -21/08/2012
i06806533
Torque Converter - Assemble - Lock Up Clutch with
Freewheel Stator
SMCS - 3101-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 3
G
8T-5096 Dial Indicator Test Group 1
5P-2390 Gauge Tool Group 1
H 1P-0520 Driver Group 1
J -
Guide Stud
(3/8 - 16 by 8 in)
2
K -
Guide Stud
(1/2 - 13 by 3 in)
3
L 2P-8312 Retaining Ring Pliers 1
Note: Cleanliness is an important factor. Before assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping cloths or rags should not be used to dry parts.
Lint may be deposited on the parts which may cause later trouble. Inspect all parts. If any parts are
worn or damaged, use new parts for replacement.
Note: Apply oil to all of the bearings before assembly.
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19. Illustration 1 g02735387
1. Install adapter (63), hub (62), and bolts (61) onto impeller (54). Tighten bolts (61) to a
torque or 105 ± 14 N·m (77 ± 10 lb ft).
Illustration 2 g02735380
2. Install bearing (60).
Illustration 3 g02735374
3. Install carrier assembly (58) and retaining ring (59) onto impeller (54).
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20. Illustration 4 g06122365
4. Raise the temperature of bearing (57). Install bearing (57) onto hub (55).
5. Install retaining ring (56A) and seal ring (56).
Illustration 5 g02734776
Illustration 6 g02735333
6. Install hub (55) and retaining ring (56) onto impeller (54).
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21. Illustration 7 g02752296
7. Install seals (64).
Illustration 8 g02732255
8. Attach Tooling (A) and a suitable lifting device to impeller (54). The weightof impeller (54)
is approximately 27 kg (60 lb).
9. Position impeller (54) onto shaft assembly (39).
Illustration 9 g02731806
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22. Illustration 10 g06122374
Typical Example
10. Install retaining ring (53) (not shown) and plate (52) onto stator (46).
11. Install freewheel cam (51), freewheel rollers (50), and springs (49).
Note: Springs (49) must be installed with the maximum number or loops to the outside.
12. Install plate (48) and retaining ring (47).
Illustration 11 g02731802
Illustration 12 g06122399
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23. 13. Install stator assembly (46).
14. Install bearing (45) race (44), and outer race (44A).
Illustration 13 g02744699
Illustration 14 g06122404
15. Install hub (43) and turbine (42).
16. Use two of bolts (36) to align the holes.
17. Use suitable blocking to support the bottom of shaft assembly (39). Install plate
(41),retaining ring (40), and ring seal (39A).
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24. Illustration 15 g06122416
18. Install springs (36A) and (36B) inside of springs (36). Install springs (36) in an alternating
pattern. An example would be to install a spring (36) with a spring (36A) inside. The next
one would be to install a spring (36) with a spring (36B) inside.
Illustration 16 g06122422
19. Install plate (38), coupling assembly (37), and bolts (36). Tighten bolts (36) to a torque of
60 ± 7 N·m (44 ± 5 lb ft).
Note: Plate (38) has an O-ring groove that is not used.
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25. Illustration 17 g06122434
20. Install disk (33), races (34), and bearing (35).
Illustration 18 g02731059
21. Lower the temperature of bushing (31). Install bushing (31) into housing (27).
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26. Illustration 19 g02730689
22. Install seals (29) onto piston (28). Install plate (30), piston (28), and housing (27).
Note: Plate (30) has an O-ring groove that is not used.
Illustration 20 g02730012
23. Tighten bolts (26). Tighten bolts (36) to a torque of 60 ± 7 N·m (44 ± 5 lb ft).
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27. Illustration 21 g02735357
24. Lower the temperature of race (25A). If necessary, use the driver group from Tooling (D)
and a suitable press to install race (25A) into gear (25).
Illustration 22 g02729366
25. Use a suitable lifting devise to reposition the torque converter, as shown. The weight of the
torque converter is approximately 1157 N (260 lb).
26. Install drive gear (25) and bolts (24). Tighten the bolts to a torque of 50 ± 7 N·m
(37 ± 5 lb ft).
Illustration 23 g00872709
27. Install studs (23) in torque converter housing assembly (2). Tighten the studs to a torque of
100 ± 15 N·m (74 ± 11 lb ft).
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28. Suggest:
If the above button click is invalid.
Please download this document
first, and then click the above link
to download the complete manual.
Thank you so much for reading
29. Illustration 24 g00872711
28. Install retaining ring (21) in the groove of idler gear (13).
Illustration 25 g00872713
29. Use the proper equipment to handle bearing cup (22). Lower the temperature of bearing cup
(22). Install bearing cup (22) in idler gear (13).
Illustration 26 g00872715
30. Flip idler gear (13) to the opposite side. Install bearing cup spacer (20) in idler gear (13).
The notch in bearing cup spacer (20) must be aligned with retaining ring (21).
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