Disassembly Procedure
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Table 1
Required Tools     |
Tool     |
Part Number     |
Part Description     |
Qty     |
A     |
138-7573     |
Link Bracket     |
1     |
B     |
126-7175     |
Push-Puller Tool Gp     |
4     |
C     |
1P-2420     |
Transmission Repair Stand     |
1     |
D     |
2P-8312     |
Retaining Ring Pliers     |
1     |
F     |
9U-7480     |
Compressing Tube     |
1     |
G     |
1P-1863     |
Retaining Ring Pliers     |
1     |
H     |
9U-7479     |
Compressing Tube     |
1     |
J     |
1U-6341     |
Threaded Rod     |
1     |
K     |
5P-7970     |
Nut     |
1     |
L     |
154-6182     |
Forcing Bolt     |
1     |
Start By:
- Separate the transmission from the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Separate".
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NOTICE |
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. |
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Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.
Note: Put identification marks on all sections of the transmission for assembly purposes.
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Illustration 1 | g00984312 |
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Illustration 2 | g01272038 |
- Use Tooling (A) and a suitable lifting device to remove shaft assembly (1) from the transmission case and position shaft assembly (1) on Tooling (C) , as shown. The weight of shaft assembly (1) is approximately 50 kg (110 lb).
Note: Hold input shaft (2) away from shaft (1) for clearance.
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Illustration 3 | g00961189 |
- Use Tooling (D) to remove retaining ring (3) and remove thrust disc (4) .
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Illustration 4 | g00961435 |
- Remove gear and hub assembly (5) .
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Illustration 5 | g00961444 |
- Use Tooling (G) to remove retaining ring (6) .
- Separate hub (7) from hub assembly (5) . If necessary, remove sleeve bearing (8) .
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Illustration 6 | g00961455 |
- Remove thrust disc (9) and retainer (10) .
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Illustration 7 | g00961468 |
- Use Tooling (D) to remove retaining ring (11) .
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Illustration 8 | g00961492 |
- Use a suitable screwdriver to remove retaining ring (12) .
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Illustration 9 | g00961507 |
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Illustration 10 | g00961630 |
- Remove end plate (13) , clutch plates (14) , and friction discs (15) .
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Illustration 11 | g00961639 |
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Illustration 12 | g00961647 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) .
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) to remove retaining ring (16) . Remove Tooling (F) .
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Illustration 13 | g00961656 |
- Remove balance seal assembly (17) .
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Illustration 14 | g00961678 |
- Remove wave spring (18) .
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Illustration 15 | g00974947 |
- Remove piston assembly (19) .
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Illustration 16 | g00974948 |
- Balance seal assembly (17) . Wave spring (18) will be removed with piston (19) . Check the lips on the seals for damage or wear. Replace the seals if it is necessary.
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Illustration 17 | g00974949 |
- Use Tooling (A) and a suitable lifting device to reposition the shaft assembly, as shown. The weight of the shaft assembly is approximately 50 kg (110 lb).
- Remove three seal rings (20) . Use Tooling (D) to remove retaining ring (21) .
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Illustration 18 | g00974950 |
- Remove thrust disc (22) .
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Illustration 19 | g00974951 |
- Remove washer (23) and gear (24) .
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Illustration 20 | g00974953 |
- Remove spacer assembly (25) .
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Illustration 21 | g00974954 |
- Remove thrust disc (26) , the gear, and hub assembly (27) .
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Illustration 22 | g00974955 |
- Use Tooling (G) to remove retaining ring (28) . Separate hub assembly (27) from gear (29) . If necessary, remove sleeve bearing (30) .
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Illustration 23 | g00974956 |
- Remove thrust disc (31) and retainer (32) .
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Illustration 24 | g00974957 |
- Use Tooling (D) to remove retaining ring (33) .
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Illustration 25 | g00974958 |
- Use a screwdriver to remove retaining ring (34) .
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Illustration 26 | g00974959 |
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Illustration 27 | g00974960 |
- Remove end plate (35) , clutch plates (36) , and friction discs (37) .
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Illustration 28 | g00974961 |
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Illustration 29 | g00974962 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Position the shaft assembly with the opening in retaining ring (38) in line with the opening in Tooling (F) .
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown).
- Use Tooling (D) to remove retaining ring (38) and remove Tooling (F) .
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Illustration 30 | g00974963 |
- Remove balance seal assembly (39) .
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Illustration 31 | g00974964 |
- Remove wave spring (40) .
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Illustration 32 | g00974965 |
- Remove piston seal (41) .
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Illustration 33 | g00988356 |
- Remove seal rings (41A) and (41B) from piston (41) . Replace the seals, if necessary.
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Illustration 34 | g00974967 |
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Illustration 35 | g01272041 |
- Use Tooling (A) and a suitable lifting device in order to remove shaft assembly (42) and position shaft assembly (42) on Tooling (C) , as shown. The weight of shaft assembly (42) is approximately 41 kg (90 lb).
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Illustration 36 | g00975449 |
- Use Tooling (D) to remove retaining ring (43) and remove thrust disc (44) .
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Illustration 37 | g00975452 |
- Remove gear and hub assembly (45) .
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Illustration 38 | g00975454 |
- Use Tooling (G) to remove retaining ring (46) . Separate hub assembly (45) from gear (47) . Remove sleeve bearing (48) , if necessary.
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Illustration 39 | g00975456 |
- Remove thrust disc (49) and retainer (50) .
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Illustration 40 | g00975458 |
- Use Tooling (D) to remove retaining ring (51) .
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Illustration 41 | g00975463 |
- Use a suitable screwdriver to remove retaining ring (52) .
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Illustration 42 | g00975467 |
- Remove one end plate (53) , clutch plates (54) , and friction discs (55) .
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Illustration 43 | g00975553 |
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Illustration 44 | g00975555 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Position the shaft so the opening in retaining ring (56) will line up with the opening in Tooling (F) .
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) to remove the retaining ring (56) . Remove Tooling (F) .
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Illustration 45 | g00975558 |
- Remove balance seal assembly (57) .
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Illustration 46 | g00975562 |
- Remove wave spring (58) .
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Illustration 47 | g00975564 |
- Remove piston assembly (59) .
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Illustration 48 | g00988355 |
- Remove seal rings (59A) , and (59B) from piston (59) . Replace the seals if it is necessary.
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Illustration 49 | g00975570 |
- Use Tooling (A) (not shown) and a suitable lifting device in order to position the shaft assembly on Tooling (C) , as shown. The weight of the shaft assembly is approximately 43 kg (95 lb).
- Remove three seal rings (60) . Use Tooling (D) to remove retaining ring (61) .
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Illustration 50 | g00975576 |
- Remove thrust disc (62) and gear assembly (63) .
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Illustration 51 | g00975578 |
- Remove sleeve bearings (64) , if necessary.
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Illustration 52 | g00975579 |
- Remove thrust disc (65) and retainer (66) .
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Illustration 53 | g00975584 |
- Use Tooling (D) to remove retaining ring (67) . Use a suitable screwdriver to remove retaining ring (68) .
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Illustration 54 | g00975585 |
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Illustration 55 | g00975587 |
- Remove end plate (69) , clutch plates (70) , and friction discs (71) .
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Illustration 56 | g00975588 |
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Illustration 57 | g00975810 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Position the shaft assembly so the opening in retaining ring (72) will be in line with the opening in Tooling (F) .
- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (G) to remove retaining ring (72) . Remove Tooling (F) .
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Illustration 58 | g00975811 |
- Remove balance seal assembly (73) .
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Illustration 59 | g00975812 |
- Remove wave spring (74) .
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Illustration 60 | g00975818 |
- Remove piston seal (75) .
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Illustration 61 | g00988354 |
- Remove seal rings (76) and (77) from piston (75) . Replace the seals if it is necessary.
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Illustration 62 | g00975828 |
- Remove input shaft group (78) .
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Illustration 63 | g00975867 |
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Illustration 64 | g00976174 |
- Use a suitable press to remove carrier (80) , bearing cone (81) , and gear (82) from shaft (78) .
- Remove seal ring (79) .
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Illustration 65 | g00976184 |
- Reposition shaft (78) (not shown) in order to remove bearing cone (83) , and gear (84) .
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Illustration 66 | g01272168 |
- Disconnect harness assembly (86) and remove sensor (85) .
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Illustration 67 | g00976215 |
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Illustration 68 | g00976227 |
- Use Tooling (A) and a suitable lifting device to remove shaft assembly (87) and position shaft assembly (87) on Tooling (C) , as shown. The weight of shaft assembly (87) is approximately 82 kg (180 lb).
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Illustration 69 | g00976228 |
- Use Tooling (D) to remove retaining ring (88) . Remove thrust disc (89) .
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Illustration 70 | g00976229 |
- Remove gear (90) .
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Illustration 71 | g00976230 |
- Use Tooling (D) to remove retaining ring (91) .
- Separate hub assembly (92) from gear (90) . If necessary, remove sleeve bearing (93) .
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Illustration 72 | g00976232 |
- Remove thrust disc (94) and retainer (95) .
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Illustration 73 | g00977380 |
- Use Tooling (D) to remove retaining ring (96) .
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Illustration 74 | g00977422 |
- Use a suitable screwdriver to remove retaining ring (97) .
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Illustration 75 | g00977424 |
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Illustration 76 | g00977433 |
- Remove end plate (98) , clutch plates (100) , and disc assembly (99) .
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Illustration 77 | g00977426 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown).
- Use Tooling (D) to remove retaining ring (101) . Release the pressure on the wave spring and remove Tooling (F) .
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Illustration 78 | g00977438 |
- Remove balance seal assembly (102) .
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Illustration 79 | g00977441 |
- Remove wave spring (103) .
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Illustration 80 | g00977444 |
- Apply suitable air pressure to the passage in order to move piston (104) upward. Remove piston (104) from the shaft.
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Illustration 81 | g00977446 |
- Balance seal assembly (102) , wave spring (103) , and piston (104) upon removal. Check the lips on the seals for damage or wear. Replace the seals, if necessary.
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Illustration 82 | g01272046 |
- Use Tooling (A) and a suitable lifting device to rotate shaft assembly (78) to the opposite side on Tooling (C) . The weight of shaft assembly (78) is approximately 45 kg (100 lb).
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Illustration 83 | g00977453 |
- Remove seal rings (105) .
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Illustration 84 | g00977455 |
- Remove thrust disc (106) .
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Illustration 85 | g00979038 |
- Use Tooling (D) to remove retaining ring (107) .
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Illustration 86 | g00979043 |
- Remove gear (108) .
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Illustration 87 | g00979049 |
- Remove thrust disc (109) .
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Illustration 88 | g00979054 |
- Remove gear and hub assembly (110) .
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Illustration 89 | g00979056 |
- Use Tooling (G) to remove retaining ring (111) .
- Separate hub assembly (112) from gear (110) .
- If necessary, remove sleeve bearing (113) .
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Illustration 90 | g00979059 |
- Remove thrust disc (114) and ring retainer (115) .
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Illustration 91 | g00979060 |
- Use a suitable screwdriver to remove retaining ring (116) .
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Illustration 92 | g00979063 |
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Illustration 93 | g00979064 |
- Remove end plate (117) , clutch plates (118) , and friction discs (119) .
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Illustration 94 | g00979070 |
- Use Tooling (G) to remove retaining ring (120) .
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Illustration 95 | g00979073 |
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Illustration 96 | g00979077 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Position the shaft assembly so retaining ring (121) lines up with the opening on Tooling (H) .
- Install Tooling (H) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) in order to remove retaining ring (121) . Remove Tooling (H) .
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Illustration 97 | g00979089 |
- Remove balance piston (122) .
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Illustration 98 | g00979091 |
- Remove wave spring (123) .
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Illustration 99 | g00979099 |
- Remove piston (124) .
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Illustration 100 | g00984232 |
- Balance seal assembly (124) , wave spring (123) , and piston (122) upon removal. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.
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Illustration 101 | g00984236 |
- Remove seals (124) and (126) from piston (124) .
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Illustration 102 | g00984239 |
- Remove thrust disc (127) from transmission case (132) .
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Illustration 103 | g00984240 |
- Remove bearings (128) , (129) , and (130) from transmission case (132) .
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Illustration 104 | g00984243 |
- Use Tooling (B) to remove bearing cone (131) from shaft (133) in transmission case (132) .
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Illustration 105 | g01272211 |
- Rotate the transmission case. Remove bolts (135A) and brake drum (135) . Remove the yoke and brake drum (135) .
- Remove bolt (134) , the retainer, and yoke (134A) .
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Illustration 106 | g00984245 |
- Remove bolts (136) . Remove parking brake group (137) .
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Illustration 107 | g00984247 |
- Remove bolts (138) .
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Illustration 108 | g00984248 |
- Use Tooling (L) to remove bearing cage (139) .
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Illustration 109 | g00984249 |
- Remove shims (140) , bearing cup (141) , seal (142) , and seal (143) from bearing cage (139) .
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Illustration 110 | g00984251 |
- Remove shaft assembly (133) .
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Illustration 111 | g00984252 |
- Use a suitable press to remove bearing cone (145) and gear (144) from shaft assembly (133) .
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Illustration 112 | g01272164 |
- Remove bolts (147) and bearing cage (146) from transmission case (132) .
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Illustration 113 | g01272199 |
- Remove bearing cup (150) , seal (149) , and shims (148) from bearing cage (146) .
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Illustration 114 | g00984255 |
- Remove bolts (151) and remove cover (152) .
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Illustration 115 | g00984256 |
- Remove suction screen (153) and magnetic screen (154) .
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Illustration 116 | g00960379 |
- Remove bearings (156) and (157) from cover (155) .
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Illustration 117 | g00960522 |
- Remove the torque converter from cover (155) .
- Remove bearing (158) , bearing cup (159) , and seal (160) from cover (155) .