572R Pipelayer Power Train Caterpillar

Disassembly Procedure

Start By:

1. Separate the transmission and bevel gear. Refer to Disassembly and Assembly, "Transmission and Bevel Gears - Separate".

Note: The transmission modulating valves must be recalibrated if any of the following procedures are performed:

• The transmission modulating valve and/or the solenoid is replaced.

• The transmission is serviced or replaced.

• The ECM is replaced.

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Illustration 1	g00595589

1. Put the transmission in the correct position on Tooling (A). Put marks on all the housings for alignment during the assembly procedure.

2. Remove small O-ring seals (1) and large O-ring seal (2) from the transmission cover.
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   Illustration 2	g00595592

3. Remove the plugs and fitting (5).

4. Remove the bolts and retainers (4).

5. Remove tubes (3) and the seals from the tubes.
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   Illustration 3	g00595597

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   Illustration 4	g00595602

6. Remove locknut (6). Push connector (7) out of the case.

7. Disconnect harness assembly (8).
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   Illustration 5	g00595604

8. Remove 9/16 inch bolts (9) and control valve (10).
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   Illustration 6	g00595608

9. Remove bolt (11) and tube assembly (12).

10. Remove the O-ring seal from tube assembly (12).
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    Illustration 7	g00595609

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    Illustration 8	g00595610

11. Attach Tooling (B) and a suitable lifting device to the planetary group. Remove bolts (13) that hold the planetary group to the transmission cover. Remove the planetary group. The weight of the planetary group is approximately 341 kg (751.8 lb).
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    Illustration 9	g00648092

12. Attach Tooling (B) and a suitable lifting device to the transmission cover. Remove the transmission cover from Tooling (A). The weight of transmission cover (15) is approximately 100 kg (220.5 lb).

13. Remove the bolts and cover (14) of the suction screen and the O-ring seal from the transmission cover.

14. Remove the suction screen from transmission cover (14).
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    Illustration 10	g00648094

15. Put transmission planetary group (16) in position on Tooling (A). Use the bolts and nuts (17) to fasten the planetary group to Tooling (A).
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    Illustration 11	g00595611

16. Remove harness assemblies (20) from the clips on the back side of plate assembly (19). Remove bolts (18), the washers, and plate assembly (19) from planetary group (16).
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    Illustration 12	g00595612

17. Remove guard (21) and the bracket with sensors (22) from the planetary group.
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    Illustration 13	g00595614

18. Use Tooling (C) to remove retaining ring (23) and rotor (24).
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    Illustration 14	g00595678

19. Remove ring (25) and rotor (26).
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    Illustration 15	g00595680

20. Use Tooling (C) to remove retaining ring (27). Remove bolts (28) and the washers from manifold (29).
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    Illustration 16	g00595682

21. Install Tool (B) and a suitable lifting device to manifold (29). Remove manifold (29). The weight of manifold (29) is approximately 22 kg (48.5 lb).
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    Illustration 17	g00648095

22. Use Tooling (D) to remove bearing (30) from manifold (29).

23. Remove bearing (31) from manifold (29).
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    Illustration 18	g00648096

24. Remove first clutch gear (31) and the housing assembly. The weight of first clutch gear (31) and the housing assembly is approximately 31 kg (68.3 lb).

25. Remove springs (32) and dowels (34).

    Note: The discs and the plates from the individual clutches must be kept in the correct order. The discs and the plates must be kept with the original clutch housings. The different clutches use different friction material. The discs and the plates must not be mixed together.

26. Remove the two discs and one plate (33). The two discs and plate (33) are the second speed clutch.
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    Illustration 19	g00648098

27. Remove retaining ring (34) and housing (35) from first clutch gear (31).

28. Remove the four discs and the three plates from first clutch gear (31).
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    Illustration 20	g00648099

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    Do not remove the retaining ring until the spring force has been released. Failure to do so could result in personal injury or death. In order to prevent this, use a suitable press to hold the spring force while the retaining ring is removed. Slowly release the spring tension with the press after the retaining ring has been removed.

29. Put housing (35) in a press, as shown. Compress the springs under plate (36). Remove retainer ring (37). Slowly release the spring pressure. Remove plate (36) and the three spring plates under plate (36).
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    Illustration 21	g00648100

30. Remove piston (39) from housing (35). Remove ring (40) and seal (38) from the piston.
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    Illustration 22	g00648103

31. Turn over the housing. Remove seal rings (41) from carrier (42).

    Note: Carrier (42) will be destroyed if the carrier is removed from the housing.

32. If carrier (42) must be removed, use a hammer and a chisel to break the carrier. Remove the carrier. After the carrier is removed, remove the dowel that holds the carrier in position.
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    Illustration 23	g01033377

33. Use Tooling (E) to hold the two pistons in clutch housing (43).

34. Attach Tooling (F) and a suitable lifting device to clutch housing (43). Remove clutch housing (43). The weight of clutch housing (43) and the piston is approximately 46 kg (101.4 lb).
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    Illustration 24	g00648119

35. Remove pistons (45) and (47) from clutch housing (43).

36. Remove seal rings (44) and (46) from pistons (45) and (47).
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    Illustration 25	g00648120

37. Remove springs (48).

38. Remove three discs (49) and the two plates.
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    Illustration 26	g00648123

39. Use Tooling (C) to remove retaining ring (50).

40. Remove gear (51) and planetary carrier (52).
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    Illustration 27	g00648125

41. Use a hammer and a punch to push pins (56) into shafts (53).

42. Remove shafts (53), gears (54), and thrust washers (55) and (58) from planetary carrier (52). Remove bearings (57) from gears (54).

43. Remove pins (56) from shafts (53).

44. Install small screwdrivers in teeth (X) around the planetary carrier. This will compress the retaining ring. Remove gear (59) from planetary carrier (52).
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    Illustration 28	g01033379

45. Put wood blocks under reverse clutch housing (62).

46. Remove bolts (60). Use Tooling (G) to hold the piston in forward clutch housing (61).

47. Attach Tooling (H) and a suitable lifting device to the piston and forward clutch housing (61). Remove the piston and forward clutch housing (61). The weight of the piston and forward clutch housing (61) is approximately 26 kg (57.3 lb).
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    Illustration 29	g00648132

48. Remove piston (63) from forward clutch housing (61).

49. Remove seal ring (64) and seal ring (65) from piston (63).
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    Illustration 30	g00648133

50. Remove dowels (68) and springs (70).

51. Remove four discs (67), the three plates, ring gear (66), and plate assembly (69).
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    Illustration 31	g00648135

52. Remove four discs (71) and the three plates from reverse clutch housing (62).
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    Illustration 32	g00648136

53. Use Tooling (C) to remove retaining ring (72). Retaining ring (72) holds the shaft and the planetary carrier to reverse clutch housing (62).
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    Illustration 33	g00648137

54. Use a suitable lifting device to remove output shaft (73) and the planetary carrier from reverse clutch housing (62). The weight of output shaft (73) and the planetary carrier is approximately 70 kg (154.3 lb).
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    Illustration 34	g00648139

55. Remove piston (74) from reverse clutch housing (62).

56. Remove seal ring (75) and seal ring (76) from the piston.
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    Illustration 35	g00648140

57. Turn over the reverse clutch housing. The weight of the reverse clutch housing is 42 kg (92.6 lb). Use Tooling (D) to remove snap ring (77).

58. Remove bearing (78).
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    Illustration 36	g00648141

59. Remove seal (80), seal rings (79), and seal ring (81) from the shaft and the planetary carrier.
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    Illustration 37	g00648145

60. Turn over the output shaft, the planetary carriers, and the gears. Position the components on wood blocks, as shown.

61. Remove seal (82) from output shaft (73).

62. Remove seal ring (84) from the planetary carrier.

63. Remove retaining ring (83) that holds output shaft (73) to the planetary carrier.

64. Remove output shaft (73) from the input shaft and from the planetary carrier.
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    Illustration 38	g00648146

65. Use Tooling (C) to remove retaining ring (85) from output shaft (83). Remove gear (86) and bearing (87) from the output shaft.
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    Illustration 39	g00648149

66. Remove bearing (88) from output shaft (73).
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    Illustration 40	g00648150

67. Use Tooling (C) to remove retaining ring (92). Retaining ring (92) holds gear (91) in position on input shaft (90). Remove gear (91).

68. Use two people in order to remove the planetary carrier from the input shaft. The weight of planetary carrier (89) is approximately 26 kg (57.3 lb).
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    Illustration 41	g00648151

69. Use Tooling (J) to compress retaining ring (93). Remove gear (94) from the planetary carrier.
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    Illustration 42	g00648153

70. Remove retaining ring (95). Remove bearing (97) and the gear as a unit from the planetary carrier.

71. Remove bearing (97) from gear (96).

72. Use a hammer and a punch to push pin (98) into the planetary gear shafts.
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    Illustration 43	g00648154

73. Remove planetary gear shafts (102), gears (99) and (101), and thrust washers (103) from the planetary carrier.

74. Remove bearings (100) from gears (99) and (101).

75. Remove pins (104) from planetary gear shafts (102).
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    Illustration 44	g00648158

76. Remove planetary carrier (105) from input shaft (90).
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    Illustration 45	g00648159

77. Use Tooling (D) to remove retaining ring (106). Remove bearing (107).

78. Use a hammer and a punch to push pins (108) into the planetary gear shafts.
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    Illustration 46	g00648160

79. Remove planetary gear shafts (109), gears (110), and thrust washers (112).

80. Remove bearings (111) from gears (110).

81. Remove pins (113) from the planetary gear shafts.
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    Illustration 47	g00648161

82. Remove O-ring seal (115) from input shaft (90).

    Note: Carrier (114) will be damaged if the carrier is removed.

83. If necessary, remove carrier (114) from input shaft (90).