Caterpillar Cat 992 WHEEL LOADER (Prefix 25K) Service Repair Manual (25K00001-00698)

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Product WHEEL LOADER Model 992 WHEEL LOADER
25K Configuration 992 WHEEL LOADER
25K00001-00698 (MACHINE)
Disassembly and Assembly 992 WHEEL LOADER POWER
TRAIN Media Number -REG00919-00 Publication Date
-01/04/1971
Date Updated -21/07/2004
REG009190006
Brake Linings And Expander Tubes SMCS - 4254-11
4254-12 4270 Remove Brake Linings And Expander
Tubes
preparatory step a) remove tires and wheel
assemblies
NOTE Brake lining wear can be checked without
removing the tire and wheel assembly. Apply the
brakes and observe the position of edge (2) of
the brake shoe. Maximum permissible lining wear
is indicated when edge (2) of shoe contacts face
(1) of retracting spring. However, linings
should always be replaced before this point is
reached. 1. Remove the brake linings from the
frame assemblies as follows NOTICE
2
When removing brake linings and frame assemblies,
be careful not to get dirt or other contaminants
on wheel outer bearing cone and Duo- Cone seal.

• Place a screwdriver against the hook of
  retracting spring (5), and insert the spring
  inserter (A) between the hook of spring and the
  frame assembly.
• Using the screwdriver, drive the spring through
  the frame assembly and out the opposite side.
• Lift the brake lining out of frame assembly.
• NOTICE
• Always reline with full sets of linings only, and
  install each new lining with a new retracting
  spring. In most cases, it is advisable to replace
  expander tubes when replacing linings.

1. Remove the mounting bolts (4) from each side of
   frame assemblies (3), and remove the two frame
   assemblies.
2. Remove the expander tube as follows

1. Using two pry bars, raise the expander tube until
   nozzle (6) clears the hole in spindle.
2. Slide the tube off the spindle as far as possible.

3
c) Pull the second nozzle (6) out of spindle, and
remove the expander tube.
Install Brake Linings And Expander Tubes

• Thoroughly clean the outside diameter and the
  nozzle holes in spindle. Apply a thin coat of
  7F2770 Rubber Cement to the inside of expander
  tube and to outside of spindle at four locations.
  The cement (1) should be applied 1 in. (2,5 cm)
  from nozzles and nozzle holes in a pattern 2 in.
  (5 cm) wide by 4 in. (10 cm) long as shown.
• NOTE The surface of expander tube and spindle
  must be clean, dry, and free of dust. The cement
  must be applied at a temperature above 65F
  (18C) and should be allowed to dry until it
  becomes tacky but does not transfer to the hand
  when touched.
• Install the expander tube as follows

a) Install and lubricate the O-ring seals on
expander tube nozzles. Carefully insert the
nozzle (2) in the spindle.
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b) Position the top nozzle on top of spindle.
Using two bars, slide expander tube in place
until nozzle is near hole in the spindle.

• Reposition the two bars to raise nozzle (3).
  Slide the expander tube until nozzle is directly
  over the hole. Carefully remove the bars, and
  seat the nozzle into the hole.
• Using the hand, firmly apply pressure at the four
  cemented locations to properly seat the expander
  tube to the spindle.
• 3. Position the brake frame assemblies on
  spindle, and install mounting bolts. Tighten
  bolts to 375
• 35 lb. ft. (51,9 4,8 mkg).

• NOTE The brake frame assemblies should be
  installed with notches (4) in the 3 o'clock and 9
  o'clock positions for the right rear and right
  front. Notches should be 6 o'clock and 12 o'clock
  positions on left rear and left front frame
  assemblies.
• 4. Position the lining (5) in frame assembly.
  Using spring inserter (A) and a soft hammer,
  install the new retracting spring. Repeat
  procedure until all linings are installed.
• concluding steps
• install tires and wheel assemblies
• bleed brake system (See BRAKE SYSTEM BLEEDING in
  TESTING AND ADJUSTING)

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Product WHEEL LOADER Model 992 WHEEL LOADER
25K Configuration 992 WHEEL LOADER
25K00001-00698 (MACHINE)
Disassembly and Assembly 992 WHEEL LOADER POWER
TRAIN Media Number -REG00919-00 Publication Date
-01/04/1971
Date Updated -21/07/2004
REG009190007
Wheel Bearings And Duo-Cone Seals SMCS - 4204-11
4204-12 4209 Remove Wheel Bearings And Duo-Cone
Seals
preparatory step a) remove tires and wheel
assemblies
1. Install tool setup (A), and remove the wheel
outer bearing cup.
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1. Remove the outer metal floating ring seal (1).
2. Install two 3/8"-16NC forcing screws in seal
   retainer (2), and separate the retainer from
   wheel.

4. Using tool setup (B), remove the wheel inner
bearing cup.

1. Remove the wheel inner bearing cone (3) from the
   spindle.
2. Remove the metal floating ring seal (4) from the
   spindle.

Install Wheel Bearings And Duo-Cone Seals
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1. Using seal installer (A), install the metal
floating ring seal on spindle.

1. Install the wheel, inner bearing cone (1) on the
   spindle.
2. Install the bearing cups in the wheel.

1. Position the seal retainer (2) in wheel with
   dowels in retainer, aligned with dowel holes (3)
   in wheel.
2. Using seal installer (A), install the metal
   floating ring seal in the wheel. concluding step

9
a) install tires and wheel assemblies
Copyright 1993 - 2021 Caterpillar Inc. All
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Product WHEEL LOADER Model 992 WHEEL LOADER
25K Configuration 992 WHEEL LOADER
25K00001-00698 (MACHINE)
Disassembly and Assembly 992 WHEEL LOADER POWER
TRAIN Media Number -REG00919-00 Publication Date
-01/04/1971
Date Updated -21/07/2004
REG009190008

• Spindles
• SMCS - 4205-11 4205-12
• Remove Spindle
• preparatory step
• a) remove brake linings and expander tubes
• Remove the wheel inner bearing cone and the metal
  floating ring seal from the spindle.
• Remove the brake bleeder valve, and pull the tube
  out of spindle.

1. Disconnect brake oil supply line (3), and remove
   tube (1).
2. Install two 3/4"-10NC forged eyebolts in top of
   spindle, and attach a hoist.
3. Remove the spindle retaining nuts (2).

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6. Remove spindle (4) and adapter (5)-weight 575
lbs. (260 kg). NOTICE Keep the spindle level
during removal and installation in order to
prevent adapter (5) from falling off spindle
retaining studs.
7. Attach a hoist and remove the adapter from the
spindle-weight 150 lbs. (68 kg).
Install Spindle

1. Using a hoist, position the adapter (1) on the
   spindle.
2. Install the adapter and spindle on the axle
   housing.

12

• Install spindle retaining nuts. Tighten nuts (2)
  to 640 80 lb. ft. (88,5 11,1 mkg).
• Install the oil tube in spindle, and connect the
  brake oil supply line.
• Install tube (3) in spindle, and install the
  brake bleeder valve.
• Using seal installer (A), install the metal
  floating ring seal in spindle. Install the wheel
  inner bearing cone on spindle.
• concluding step
• a) install brake linings and expander tubes

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Product WHEEL LOADER Model 992 WHEEL LOADER
25K Configuration 992 WHEEL LOADER
25K00001-00698 (MACHINE)
Disassembly and Assembly 992 WHEEL LOADER POWER
TRAIN Media Number -REG00919-00 Publication Date
-01/04/1971
Date Updated -21/07/2004
REG009190009
Front Differential And Carrier Assembly SMCS -
3258-11 3258-12 Remove Front Differential And
Carrier Assembly

• preparatory step
• a) remove front axles
• Raise the bucket, and install the lift arm
  supports (A).
• Drain the front axle housing - capacity 16 U.S.
  Gal. (61 liters).

3. Remove the front differential cover mounting
bolts (1). Install two 1/2"-13NC forged eyebolts
in cover to separate cover from axle housing.
Attach a hoist and remove the cover-weight 150
lbs. (68 kg).
14

• Loosen the locknut on bolt (3), and screw the
  bolt into axle housing.
• Rotate the ring gear (2) until tabs (4) on the
  differential housing are in horizontal position.
• NOTICE
• Do not attempt to remove differential with tabs
  (4) contacting the differential lifting adapter
  (A).

6. Position the differential lifting adapter (B)
under the differential, and tighten bolts (8)
securely against the differential.

1. Disconnect the front drive shaft universal joint
   (5) from the differential.
2. Remove the differential-to-axle housing mounting
   bolts (6).
3. Install two of the mounting bolts in forcing
   screw holes (7), and separate differential from
   axle housing.

10. Using differential lifting adapter (B),
remove the differential-weight 1100 lbs. (500 kg).
15
NOTICE Always keep the differential level during
removal and installation.
Install Front Differential And Carrier Assembly

1. Place the differential on the differential
   lifting adapter (B), and tighten the bolts (1)
   securely against the differential.
2. Install two 1/2"-13NC guide bolts (2) in the
   carrier housing.
3. Position the differential in the axle housing
   with pin (3) in axle housing aligned with hole in
   carrier housing.
4. Remove the two guide bolts (2), and install the
   differential-to-axle housing mounting bolts.
5. Clean the mating surfaces of universal joint and
   differential flange. Coat the threads of
   retaining bolts with a multi-purpose grease.

6. Connect the front drive shaft universal joint
to the differential. Tighten retaining bolts (4)
to 225 20 lb. ft. (31,2 2,8 mkg).
16
7. Back the bolt (5) out until it touches the
differential, and tighten the locknut. NOTICE D
o not overtighten bolt against the differential.

• Attach a hoist and position the cover (6) in axle
  housing. Install cover mounting bolts.
• Fill the front axle housing with oil to the
  specified level.
• Remove the lift arm supports (A), and lower the
  bucket to the ground. concluding step
• a) install front axles

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
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Product WHEEL LOADER Model 992 WHEEL LOADER
25K Configuration 992 WHEEL LOADER
25K00001-00698 (MACHINE)
Disassembly and Assembly 992 WHEEL LOADER POWER
TRAIN Media Number -REG00919-00 Publication Date
-01/04/1971
Date Updated -21/07/2004
REG009190010

• Rear Differential And Carrier Assembly
• SMCS - 3258-11 3258-12
• Remove Rear Differential And Carrier Assembly
• preparatory step
• a) remove rear axles
• Apply the foot brakes repeatedly (with diesel
  engine stopped) until brake oil pressure gauge
  indicates zero oil pressure.
• Drain the rear axle housing-capacity 11 U.S. GAL.
  (42 liters).

3. Using an OTC Model 1790 Lo-Lift Transmission
Jack (A), remove the transmission guard (2)-
weight 375 lbs. (170 kg).
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4. Position a floor jack under driveshaft, and
remove retaining bolts (1). Remove the driveshaft
(3) -weight 95 lbs. (43 kg).

1. Remove rear axle housing oil filler pipe (7).
2. Disconnect the support bearing lubrication line
   (8) from top of rear support (6). Disconnect
   support bearing lubrication line from top of
   front support.
3. Disconnect the brake oil supply line from top
   front of axle housing.

Be sure brake oil pressure has been relieved
before disconnecting supply line.

1. Position transmission jack (A) under
   differential. Secure the differential to jack.
2. Block the front and rear of both tires. Remove
   the front and rear support-to-frame mounting
   bolts and nuts (9) and (10).
3. Raise the rear of machine approximately 8 in. (20
   cm), and install floor stands under rear of
   machine.
4. Remove blocks from rear of tires, and roll the
   axle housing and wheel assembly to the rear of
   machine as far as possible. Reposition blocks
   under both tires.
5. Remove carrier assembly-to-axle housing retaining
   bolts (4). Install three of the retaining bolts
   in forcing screw holes (5), and separate carrier
   assembly from axle housing. Remove the rear
   differential-weight 1200 lbs. (540 kg).

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Install Rear Differential And Carrier Assembly
1. Remove the cover (1) and shims from the rear
axle housing.

1. Using an OTC Model 1790 Lo-Lift Transmission Jack
   (A), position the differential in the rear axle
   housing.
2. Install the carrier assembly-to-axle housing
   retaining bolts. Tighten bolts to 350 35 lb.
   ft. (48,4 4,8 mkg).
3. Remove blocks from under front of tires, and roll
   the axle housing and wheel assembly into
   position under machine.
4. Lower the rear of machine onto axle housing, and
   install front and rear support-to-frame mounting
   bolts and nuts. Tighten nuts to 825 75 lb. ft.
   (114,1 10,4 mkg). Remove jack.
5. Install cover (1) without shims. Tighten the two
   retaining bolts evenly. Measure the gap between
   cover and axle housing. Remove cover.
6. Install cover (1) with shims equal in thickness
   to the measured gap plus .002 .001 in. (0,05
   0,03 mm).
7. Connect the brake oil supply line to top front of
   axle housing.
8. Connect support bearing lubrication lines to top
   of front and rear supports.

20

• Clean mating surfaces of driveshaft and flanges
  on differential and transfer gear. Lubricate
  threads of driveshaft retaining bolts with a
  multi-purpose grease.
• Using a floor jack, position driveshaft and
  install retaining bolts. Tighten bolts to 225
  20 lb. ft. (31,2 2,8 mkg).
• Install rear axle housing oil filler pipe. Using
  jack, install transmission guard.
• Fill the rear axle housing with oil to specified
  level. Bleed the air from rear brakes.
  concluding step
• a) install rear axles

Copyright 1993 - 2021 Caterpillar Inc. All
Rights Reserved. Private Network For SIS
Licensees.
Thu Nov 18 031714 UTC0800 2021
21
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Previous Screen
Product WHEEL LOADER Model 992 WHEEL LOADER
25K Configuration 992 WHEEL LOADER
25K00001-00698 (MACHINE)
Disassembly and Assembly 992 WHEEL LOADER POWER
TRAIN Media Number -REG00919-00 Publication Date
-01/04/1971
Date Updated -21/07/2004
REG009190011
Differential And Carrier Assembly SMCS - 3258-15
3258-16 Disassemble Differential And Carrier
Assembly
22
preparatory step a) remove differential and
carrier assembly NOTE The disassembly and
assembly of the rear differential is illustrated.
However, the following procedure is applicable
to the front differential except where noted.
23
1. Position the differential on tool setup (A) as
shown. Attach a hoist and remove the differential
front support (rear differential only)-weight
240 lbs. (109 kg).
2. Remove the bevel pinion cage retaining bolts.
Install two 1/2"-13NC forcing screws (1), and
separate cage (2) from carrier assembly (3).
Remove the forcing screws, and install two 1/2"-
13NC forged eyebolts. Attach a hoist and remove
the bevel pinion shaft and cage assembly-weight
160 lbs. (73 kg). Remove and tag shims (4) for
use during assembly of differential.
3. Disassemble the bevel pinion shaft and cage
assembly as follows

1. Remove the flange retaining bolts (6), retainer
   (5), and shims (7). Keep shims identified for use
   during assembly. Remove flange (8).
2. Remove retainer (9) from cage. Remove the
   lip-type seal from retainer. Remove spacer (10).

24

1. Install tool setup (B), and separate bevel pinion
   shaft (11) from cage.
2. Remove the bearing cone (12) from cage. Remove
   the two bearing cups from cage.
3. Remove shims from pinion shaft.

f) Install tool setup (C), and remove the bearing
cone (13) from bevel pinion shaft.

1. Attach a hoist and reposition the differential on
   transmission repair stand as shown. Remove lock
   wire (17), and mark bearing caps (14) and (15) to
   insure assembly of caps in original positions.
2. Remove the locks from adjusting rings (18) and
   (19).
3. Loosen the adjusting rings (18) and (19).
4. Remove the cap retaining nuts (16).
5. Remove caps (14) and (15).

1. Attach a hoist and remove the differential
   assembly (20)-weight 425 lbs. (193 kg).
2. Remove adjusting rings (18) and (19).
3. Remove bearing cages (21) and (22).

25
12. Remove the bearing cups from cages (21) and
(22).

1. Using tool setup (D), remove the large bearing
   cone (23) from differential assembly.
2. Attach a hoist and turn the differential assembly
   over.

15. Install tool setup (E), and remove the small
bearing cone (24) from differential assembly.

1. Mark the housing assemblies (25) and (28) with
   matching marks so they can be assembled in their
   original position.
2. Remove lock wire (27).
3. Remove the retaining nuts (26).

26

1. Attach a hoist and remove the bevel gear (29) and
   housing assembly (25)-weight 240 lbs. (109 kg).
2. Remove lock wire (30).
3. Remove the retaining bolts (31).
4. Using three of the retaining bolts (31) as
   forcing screws, separate the housing assembly
   (25) from bevel gear (29).
5. Remove the housing assembly (25)-weight 100 lbs.
   (45 kg) from the bevel gear (29)-weight 140 lbs.
   (64 kg).

24. Remove the thrust washer (32) and side gear
(33). Remove the spider and pinion (34) as an
assembly from housing assembly.
25. Remove thrust washers (35), pinions (36), and
floating bearings (37) from spider (38).
26. Remove the side gear (39) and thrust washer
from housing assembly.
27
27. Remove the wiper (40) from carrier assembly.
Assemble Differential And Carrier Assembly
1. Attach a hoist and position the differential
housing on the bevel gear. NOTICE Make sure
the flange on differential housing and mating
surface of bevel gear are clean and free of
burrs.
28

• Lubricate the faces of washers and the threads of
  bevel gear-to-differential housing retaining
  bolts. Install retaining bolts and washers, and
  tighten bolts evenly to 320 20 lb. ft. (44,25
  2,8 mkg). Secure the bolts in groups of six with
  lockwire.
• Check the alignment of the dowel holes in the
  bevel gear and differential housing if a new gear
  and/or housings are being installed. If the
  original bevel gear and differential housings are
  being reused, the dowels (1) must fit tight in
  both the gear and the housing. If the dowel holes
  are not perfectly aligned, or if the standard
  dowels do not fit tightly, proceed as follows
• a) Line ream the dowel hoses to a diameter of
  .9060 .0005 in. (23,01 0,0127 mm) and to a
  depth of 1.66 in. (42,2 mm).

• Install the larger service dowels flush with face
  (E) of differential housing.
• If new differential housings are being installed,
  install the thrust washer retaining dowels (2) on
  the inside of differential housings. The dowels
  should be installed so that dimension (F) is .140
• .002 in. (3,56 0,05 mm).

29
4. Lubricate the spider and pinion components
prior to assembly.
5. Install thrust washer and side gear (3) in the
differential housing (4). NOTICE When
installing side gear thrust washers and cup
thrust washers, make certain washers are seated
on the dowels in the differential housings. When
replacing side gear thrust washers and cup thrust
washers, always replace as a set-never
individually.
6. Install the floating bearings, pinions, and
cup thrust washers on spider.
7. Position the spider and pinion assembly (5) in
differential housing (4).

• Install side gear (6) and thrust washer.
• Attach a hoist and install the differential
  housing and bevel gear (7).
• NOTE Align the matching marks on the
  differential housings.

30
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1. Install retaining nuts (8). Tighten nuts to 280
   20 lb. ft. (38,7 2,8 mkg). Secure the nuts in
   groups of two with lockwire.
2. Using tool setup (B) and a torque wrench, check
   the torque required to rotate the differential
   group. The maximum torque required to rotate
   differential group through two complete
   revolutions in each direction should not exceed
   25 lb. ft. (3,5 mkg).

12. Heat the differential assembly bearing cones
in oil at a temperature of 275 F (135 C) for
ten minutes. Install the large and small bearing
cones on their respective differential housings.

1. Install the bearing cups in bearing cages (10)
   and (11).
2. Place the bearing cages on the differential
   housings, and install the adjusting rings (12)
   and (13). Do not tighten the adjusting rings.
3. Attach a hoist and position the carrier assembly
   on positioning stand (A) with input end of
   carrier assembly downward.
4. Install the wiper (9) in carrier assembly.

33
17. Attach a hoist and place the differential
assembly on carrier assembly with bearing cage
dowel holes (14) and (15) in upward position.
18. Place the bearing caps (16) and (17) in their
respective positions on the carrier
assembly. NOTICE Always install the bearing
caps back in their original locations on carrier
assembly with dowels in caps aligned with dowel
holes (14) and (15) in bearing cages.

• Install the bearing cap retaining nuts (18), and
  tighten nuts to 800 100 lb. ft. (110,6 13,8
  mkg). Install lockwire on retaining nuts.
• Attach a hoist and reposition the differential
  and carrier assemblies on the positioning stand
• (A) with input end of carrier assembly up.
• 21. Assemble the bevel pinion shaft and cage
  assembly as follows

34

• Install the bearing cups in cage (19). Heat the
  bevel pinion shaft bearing cones in oil at a
  temperature of 275 F (135 C) for ten minutes.
• Install inner bearing cone on bevel pinion shaft.
  Make sure bearing cone is seated against
  shoulder of shaft.
• Position bevel pinion shaft in cage (19). Install
  approximately .050 in. (1,27 mm) of shims (20)
  on the shaft.
• NOTE This shim thickness to be used as a
  starting point only in determining correct shaft
  end play.

1. Install bearing cone (21) on shaft. Make sure
   bearing cone is seated against shims. Install
   spacer (22) and yoke assembly. Install yoke
   assembly retainer (without shims) and the three
   bolts. Tighten bolts evenly.
2. Support cage (19) on blocks. Using tool setup
   (C), check the pinion shaft end play by raising
   and lowering pinion shaft. End play should be
   .005 .002 in. (0,13 0,05 mm).
3. If end play is not correct, remove retainer, yoke
   assembly, and spacer. Using tool setup (B),
   separate pinion shaft from cage. Add or remove
   shims as necessary to provide correct end play.
   Position the pinion shaft back in cage, and
   install outer bearing cone and spacer.

g) Using tool setup (D), install seal in retainer
(23) with lip of seal toward bearing cones.
Lubricate lip of seal. Position the retainer (23)
on cage, and install yoke assembly and retainer
(without shims). Tighten bolts to 130 20 lb.
ft. (18,0 2,8 mkg).
35
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