Required Tools | |||
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Tool | Part Number | Part Description | Qty |
A | 180-3032 | Jack Stand Gp | 1 |
B | 439-3939 | Link Bracket As | 4 |
C | 154-6182 | Forcing Bolt | 2 |
D | 154-6181 | Forcing Bolt | 2 |
E | 203-5582 | Lifting Plate | 1 |
F | FT-2769 | Table | 1 |
G | 1P-2322 | Combination Puller | 1 |
8B-7560 | Step Plate | 1 | |
H | 5P-4758 | Retaining Ring Pliers As | 1 |
J | 9U-7479 | Spring Compressor | 1 |
K | 6V-7728 | Forcing Bolt | 2 |
Start By:
- Remove the input speed sensor. Refer to Disassembly and Assembly, "Speed Sensor - Remove".
Note: Put identification marks on all hoses, on all hose assemblies, on all wires, and on all tube assemblies for installation purposes. Plug all hose assemblies and all tube assemblies to prevent fluid loss and keeps contaminants from entering the system.
Note: Cleanliness is an important factor. Thoroughly clean the exterior of the components before you begin the disassembly procedure to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.
NOTICE |
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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, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat® products. Dispose of all fluids according to local regulations and mandates. |
- Attach Tooling (B), and a suitable lifting device to the transmission. The weight of the transmission is approximately
1588 kg (3500 lb) . Position the transmission onto Tooling (A) and suitable blocking.Show/hide tableIllustration 2 g01381847 Note: Note the orientation of spacer (4).
- Remove tube assembly (4A). Remove bolt (1), retainer (2), the O-ring seal, yoke (3), lip seal (3A), and spacer (4). Remove bolts (5).
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Illustration 3 g01269753 - Use Tooling (C) to remove cage assembly (6) and the shims.
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Illustration 4 g01269755 - Remove bearing cup (7).
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Illustration 5 g01269757 - Attach Tooling (B) and a suitable lifting device to cover assembly (9). The weight of cover assembly (9) is approximately
82 kg (180 lb) . Remove bolts (8) and cover assembly (9).Show/hide tableIllustration 6 g01269759 - Remove tube assembly (10).
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Illustration 7 g01381923 - Remove bolt (11) and retainer (12). Use two people to remove gear (13). The weight of gear (13) is approximately
25 kg (55 lb) . Remove spacer (13A).Show/hide tableIllustration 8 g01382669 Note: Note the orientation of spacer (14).
- Remove bolt (16A), retainer (16), O-ring seal (15A), yoke (15), lip seal (14A), and spacer (14).
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Illustration 9 g01270506 - Attach Tooling (B) and a suitable lifting device to shaft assembly (17). The weight of shaft assembly (17) is approximately
82 kg (180 lb) . Remove shaft assembly (17).Show/hide tableIllustration 10 g01270543 - Use a suitable press to remove bearing cone (19) and gear (20) from shaft (18).
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Illustration 11 g01270563 - Remove retaining ring (21) from shaft (18).
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Illustration 12 g01270612 - Remove bolts (22). Use Tooling (C) to remove cage assembly (23) and the shims.
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Illustration 13 g01270613 - Remove bearing cup (24).
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Illustration 14 g01270714 - Use Tooling (D) to remove cage assembly (25) and the shims. Repeat for remaining cage assemblies (27) and (28).
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Illustration 15 g01270762 - Remove bearing cups (29) from cage assemblies (25), (27), and (28).
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Illustration 16 g01271784 - Attach Tooling (B) and a suitable lifting device to housing assembly (30). The weight of housing assembly (30) is approximately
431 kg (950 lb) . Remove bolts (31) and housing assembly (30).Show/hide tableIllustration 17 g01270775 - Reposition the housing assembly. Use two people to remove clutch (33). The weight of clutch (33) is approximately
25 kg (55 lb) . Remove bolts (32) and clutch (33).Note: Do not remove Bolts (X).
Show/hide tableIllustration 18 g01387415 Show/hide tablePersonal 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.
- Remove bolts (34). Remove reaction plate (35) and ring gear (36).
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Illustration 19 g01271857 - Remove discs and plates (37). Remove dowels (39), springs (38), and piston (40) from housing (41).
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Illustration 20 g01271911 - Remove ring seals (42) and (43).
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Illustration 21 g01272065 - Attach Tooling (E) and a suitable lifting device to shaft assemblies (44). The weight of shaft assemblies (44) is approximately
590 kg (1300 lb) . Remove shaft assemblies (44).Show/hide tableIllustration 22 g01273485 - Remove the ring seals from the shaft assemblies.
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Illustration 23 g01272218 - Position shaft assemblies (44) on Tooling (F). Remove Tooling (E).
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Illustration 24 g01272228 - Position shaft assembly (46). Install Tooling (G) onto bearing cone (45).
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Illustration 25 g01272299 - Remove bearing cone (45), spacer (47), spacer (48), gear (49), and spacer (50).
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Illustration 26 g01272313 - Reposition the shaft assembly. Remove bolts (51) and seal carrier (52).
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Illustration 27 g01272385 - Use Tooling (G) to remove bearing cone (53).
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Illustration 28 g01274797 - Remove bearing cone (53) and spacer (54). Remove thrust washer (56) and gear (55).
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Illustration 29 g01383808 - Remove bearings (57) and (58). Remove thrust washer (59). Use Tooling (H) to remove retaining ring (60). Remove clutch plate (61). Remove clutch discs and plates (62).
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Illustration 30 g01272577 Show/hide tablePersonal 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.
- Use a suitable press and Tooling (J) to compress spring (64). Remove retaining ring (63).
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Illustration 31 g01272604 - Remove spacer (65), seal assembly (66), and spring (67).
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Illustration 32 g01272607 - Remove piston (69). Remove ring seals (68), (70), and (71) from piston (69).
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Illustration 33 g01272726 - Slide shaft assembly (72) away from the remaining shaft assemblies.
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Illustration 34 g01272613 - Use Tooling (G) to remove bearing cone (73).
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Illustration 35 g01272849 - Remove bearing cone (73), spacer (74), spacer (75), thrust washer (76), and gear (77).
- Repeat Steps 29 through 32 for the disassembly of clutch pack (78).
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Illustration 36 g01272861 - Reposition shaft assembly (72). Remove bolts (79) and seal carrier (80). Remove spring pin (81).
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Illustration 37 g01272864 - Use Tooling (G) to remove bearing cone (82).
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Illustration 38 g01272870 - Remove bearing cone (82), spacer (83), spacer (84), and gear (85).
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Illustration 39 g01272916 - Remove gear (86), spacer (87), thrust washer (88), and gear (89).
- Repeat Steps 29 through 32 for the disassembly of clutch pack (90).
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Illustration 40 g01272944 - Position shaft assembly (91) away from the other shaft assemblies. Use Tooling (G) to remove bearing cone (92).
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Illustration 41 g01273177 - Remove bearing cone (92), spacer (93), and planetary carrier (94).
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Illustration 42 g01273209 - Drive pin (95) into shaft (96). Remove shaft (96), pin (95), gear (100), thrust discs (98), and bearings (99). Repeat for the remaining planetary gears.
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Illustration 43 g01382464 - Sun gear (103) and tube (102) are assembled with a captive retaining ring (103A). Retaining ring (103A) must be compressed with suitable rods to separate sun gear (103) and tube (102).
- Remove thrust washer (101), tube (102), sun gear (103), and retaining ring (103A). Remove thrust washer (104) and gear (105).
- Repeat Steps 29 through 32 for the disassembly of clutch pack (106).
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Illustration 44 g01273250 - Reposition shaft assembly (91) onto suitable blocking. Remove bolts (107), seal carrier (108), bolts (109), and rotor (110).
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Illustration 45 g01273255 - Use Tooling (G) to remove bearing cone (111).
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Illustration 46 g01273268 - Remove bearing cone (111), spacer (112), and planetary carrier (113).
- Repeat Step 44 for the disassembly of planetary carrier (113).
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Illustration 47 g01382587 - Remove thrust washer (114), tube (115), sun gear (116), thrust washer (117), and gear (118).
- Repeat Steps 29 through 32 for the disassembly of clutch pack (119).
Note: Note the location of spacer (120) when clutch pack (119) is disassembled.
Show/hide tableIllustration 48 g01273321 - Position shaft assembly (122). Use Tooling (G) to remove bearing cone (121) from shaft assembly (122).
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Illustration 49 g01273334 - Remove bearing cone (121), spacer (123), spacer (124), gear (125), and gear (126).
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Illustration 50 g01273402 - Remove spacer (127), thrust washer (128), and gear (129).
- Repeat Steps 29 through 32 for the disassembly of clutch pack (130).
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Illustration 51 g01273404 - Reposition shaft assembly (122). Use Tooling (G) to remove bearing cone (131).
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Illustration 52 g01273410 - Remove bearing cone (131), spacer (132), thrust washer (133), and gear (134).
- Repeat Steps 29 through 32 for the disassembly of clutch pack (135).
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Illustration 53 g01272066 - Remove bearing cups (138). Remove bolts (136) and clutch pack (137).
Note: Do not remove Bolts (Y).
- Repeat Steps 18 through 20 for the disassembly of clutch pack (137).
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Illustration 54 g01273474 - Remove covers (139) and bolts (140).
- Use Tooling (K) to remove carrier (141).
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Illustration 55 g01273481 - Remove O-ring seals (142) and lip seal (143) from carrier (141).
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