980M Tier 4 and 982M Tier 4 Wheel Loaders Power Train Caterpillar

Disassembly Procedure

Start By:

1. Separate the transmission and the output transfer gears.

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.

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Illustration 1	g01915213

1. Place the transmission assembly onto Tooling (A).
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   Illustration 2	g01915234

2. Disconnect tube assembly (1).
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   Illustration 3	g01915255

3. Install Tooling (B) and a suitable lifting device to modulating valve assembly (2). The weight of modulating valve assembly (2) is approximately 43 kg (95 lb).

4. Remove bolts (3). Remove modulating valve assembly (2).
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   Illustration 4	g01915279

5. Remove tubes (4) and the O-ring seals.
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   Illustration 5	g02505637

6. Attach Tooling (B) and a suitable lifting device to planetary group (5). The weight of planetary group (5) is approximately 565 kg (1250 lb). Remove planetary group (5) from transmission case (6).

7. Place planetary group (5) on suitable blocks.

   Note: Put alignment marks across the clutch housings for assembly purposes.

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   Illustration 6	g01886812

8. Remove bolts (7) and the washers.
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   Illustration 7	g02488677

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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.

9. Use Tooling (D) to secure the clutch piston in clutch housing (9).

10. Attach Tooling (B) and a suitable lifting device on clutch housing (9). The weight of clutch housing (9) is approximately 32 kg (70 lb).

11. Carefully remove clutch housing (9) from manifold assembly. Remove springs (8).
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    Illustration 8	g01886814

12. Remove clutch piston (11) from clutch housing (9). Remove seals (10) from the piston.
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    Illustration 9	g01886815

13. Remove friction discs (12), clutch plates (13), and dowels (14) from manifold assembly.
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    Illustration 10	g06327035

14. Remove gear (15) from the carrier assembly.
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    Illustration 11	g06327038

15. Use Tooling (E) to remove retaining ring (16) from shaft assembly. Remove the spacer under the retaining ring.

16. Remove carrier assembly (17).
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    Illustration 12	g01886819

17. Use a drift to bend locks (18) from bolts (19). Remove bolts (19), locks (18), and slinger (20) from carrier assembly.
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    Illustration 13	g01886826

18. Remove spring pin (22) from the carrier and shaft (21). Remove spring pin (22) from shaft (21).
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    Illustration 14	g01886833

19. Remove thrust discs (23) and (27) and gear (25).

20. Remove bearings (24) and (26) from gear (25).

21. Repeat Steps 18 through 20 for the removal of the remaining planetary gears.
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    Illustration 15	g06327041

22. Use Tooling (F) to remove retaining ring (28) from the housing assembly.

23. Remove gear (29).
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    Illustration 16	g06327045

24. Use Tooling (F) to remove retaining ring (30).

25. Remove bolts (31) that hold the manifold assembly to the clutch housing.
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    Illustration 17	g02488916
    Typical Example

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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.

26. Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of manifold assembly (32) is approximately 95 kg (210 lb).

27. Carefully remove manifold assembly (32) from the clutch housing. Remove O-ring seals (33).
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    Illustration 18	g01886839

28. Remove retaining ring (34) and bearing (35) from the manifold assembly.
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    Illustration 19	g06327052

29. Remove O-ring seal (36) and springs (39).

30. Remove friction discs (37) and clutch plates (38).
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    Illustration 20	g06327058

31. Remove rods (40) and dowels (41).

32. Remove clutch piston (42).
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    Illustration 21	g06327064

33. Remove seals (43) and (44) from the clutch piston.
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    Illustration 22	g06327069

34. Remove retaining ring (45) and clutch housing assembly (46).
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    Illustration 23	g06327168

35. Remove seal rings (47) from ring carrier (48).

36. Check the condition of the ring carrier (48). If ring carrier (48) is worn or damaged, use new parts for replacement. If the ring carrier is not worn or damaged, DO NOT remove ring carrier (48). Use a hammer and a chisel to break the ring carrier. Remove the ring carrier and the pin from housing assembly.
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    Illustration 24	g06327170
    Typical Example

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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.

37. Use Tooling (H), Tooling (J), and a suitable press to apply a force on plate (50) until spiral lockring (49) can be removed. Release the force. Remove the plate and three springs (51) from the housing.
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    Illustration 25	g06327172

38. Remove piston (52).
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    Illustration 26	g06327175

39. Remove seals (53) and (54).
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    Illustration 27	g06327180

40. Use tooling (F) to remove retaining ring (55). Remove clutch hub (56).
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    Illustration 28	g06327187

41. Remove friction discs (57) and plates (58).
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    Illustration 29	g06327190

42. Remove gear (59).
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    Illustration 30	g06327198
    Typical Example

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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.

43. Use Tooling (D) to hold clutch piston (61) in clutch housing (60). Attach Tooling (B) and a suitable lifting device to clutch housing (60). The weight of clutch housing (60) is approximately 39 kg (86 lb). Remove clutch housing (60).
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    Illustration 31	g06327205

44. Remove piston (62) from housing assembly.
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    Illustration 32	g06327210

45. Remove seals (63) and (64) from the piston.
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    Illustration 33	g06327360

46. Remove friction discs (66), clutch plates (65), and springs (67).
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    Illustration 34	g06327363
    Typical Example

47. Attach Tooling (B) and a suitable lifting device to carrier (68). The weight of carrier (68) is approximately 32 kg (70 lb).
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    Illustration 35	g06327421

48. Remove gear (69).
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    Illustration 36	g06327435

49. Use Tooling (E) to remove retaining ring (70) from hub (71). Remove hub (71) from the carrier.

50. Remove gear (72) from the carrier.
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    Illustration 37	g06327444

51. Remove spiral lockring (73). Remove bearing (74) from the carrier.
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    Illustration 38	g06327428

52. Remove spring pin (75) from the carrier.
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    Illustration 39	g06327426

53. Remove shaft (80), thrust discs (76) and (79), and gear (77). Remove bearing (78) from the gear (77). Remove pin (75) from shaft (80).

54. Repeat Steps 52 through 53 for the removal of the remaining gears.
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    Illustration 40	g06327449

55. Remove O-ring seal (81) from the shaft assembly.
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    Illustration 41	g06327454
    Typical Example

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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.

56. Remove bolts (82) from clutch housing (83).

57. Use Tooling (D) to hold the piston in clutch housing (83). Attach Tooling (B) and a suitable lifting device to clutch housing (83). The weight of clutch housing (83) is approximately 44 kg (97 lb).

58. Remove clutch housing (83), springs (84), and dowels (85).
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    Illustration 42	g06327457

59. Remove piston (86) from the clutch housing.
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    Illustration 43	g06327461

60. Remove seals (87) and (88) from the clutch piston.
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    Illustration 44	g06327475

61. Remove friction discs (89) and clutch plates (90).
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    Illustration 45	g06327476

62. Remove gear assembly (91) and plate assembly (92) from the clutch housing.
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    Illustration 46	g06327479

63. Remove friction plates (93) and clutch plates (94).
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    Illustration 47	g06327481

64. Attach Tooling (C) and a suitable lifting device to output shaft assembly (95). The weight of output shaft assembly (95) and the carrier is approximately 68 kg (150 lb).

65. Remove the retaining ring that holds output shaft assembly (95) in the bearing on the bottom of the clutch housing.

66. Remove output shaft assembly (95) and the carrier from the clutch housing.

67. Place output shaft assembly (95) on suitable blocks.
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    Illustration 48	g06327483

68. Use Tooling (E) to remove retaining ring (96).
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    Illustration 49	g06327484

69. Use a soft hammer to remove shaft assembly (97) from the bearing in the carrier.
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    Illustration 50	g06327487

70. Remove carrier assembly (98) from the shaft assembly.
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    Illustration 51	g06327493

71. Remove seals (101) and (102) from the carrier assembly.

72. Remove spiral lockring (99).

73. Use Tooling (G) to remove bearing (100).
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    Illustration 52	g06327529

74. Use a hammer and a punch to push spring pin (103) from the carrier assembly.
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    Illustration 53	g06327532

75. Remove shaft (108), thrust discs (104) and (107), and gear (105). Remove bearing (106) from gear (105). Remove pin (103) from shaft (108).

76. Repeat Steps 74 and 75 for the remaining gears.
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    Illustration 54	g06327538

77. Remove spacer (110) and gear (109) from the shaft assembly.
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    Illustration 55	g06327541

78. Put the shaft assembly on suitable blocks, as shown. Use two people to remove carrier assembly (111) from the shaft assembly. The weight of carrier assembly (111) is approximately 32 kg (70 lb).
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    Illustration 56	g06327543

79. Put the carrier assembly on a suitable block, as shown. Use a screwdriver to compress the retainer ring. Remove gear (112) from the carrier assembly. Remove retaining ring (113).
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    Illustration 57	g06327544

80. Remove spiral lockring (114). Use Tooling (G) to remove bearing (115) from the carrier. Remove seal rings (116).
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    Illustration 58	g06327548

81. Use a hammer and a punch to push spring pin (117) from the carrier assembly.
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    Illustration 59	g06327556

82. Remove shaft (126), thrust discs (118), (121), (122) and (125), and gears (120) and (124). Remove bearings (119) and (123) from the gears. Remove pin (117) from shaft (128).

83. Repeat Steps 81 and 82 for the remaining gears.
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    Illustration 60	g06327558

84. Remove gear (127) from the shaft assembly.

85. Remove seals (128) and (129) from the seal carrier.
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    Illustration 61	g06327563

86. Remove spiral lockring (130) from the shaft assembly.
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    Illustration 62	g06327570

87. Put shaft assembly on suitable blocks, as shown. Use a soft hammer to strike shaft assembly (132) until the bearing is removed from shaft assembly (131).
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    Illustration 63	g06327574

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    Illustration 64	g06327575

88. Use Tooling (L) to remove retaining ring (133) from the shaft assembly. Remove bearing (134). Remove O-ring seals (135) from the shaft assembly.
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    Illustration 65	g06327579

89. Use Tooling (H) and a suitable press to remove seal carrier (136) from the shaft assembly.
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    Illustration 66	g06327583

90. Use Tooling (K) to remove bearing (137) from the shaft assembly.
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    Illustration 67	g06327586

91. Remove gear (138) from the clutch housing.

92. Remove piston (139) from the clutch housing.
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    Illustration 68	g06327590

93. Remove seals (140) and (141) from the piston.
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    Illustration 69	g06327591

94. Remove spiral lockring (142). Use Tooling (G) to remove bearing (143) from the housing.