12/01/2022 01:21 SIS 2.

2007/08/29 Transmission - Disassemble (RENR8986-01)

SMCS - 3030 i02840379

Disassembly Procedure
Required Tools    
Tool     Part Number     Part Description     Qty    
A   138-7573     Link Bracket     1  
3H-0465     Push-Puller Plate     4  
5F-7344 Puller Block     1  
B   5P-8715 Forcing Bolt     1  
8B-7550 Push-Puller Leg     2  
8H-0663 Bearing Puller Gp     1  
C   1P-2420     Transmission Repair Stand     1  
D   2P-8312     Retaining Ring Pliers     1  
E   8S-2328     Dial Indicator Gp     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  

Table 1

Start By:

A. Separate the transmission from the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Separate".

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.

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

1. Install Tooling (A) and a suitable lifting device to shaft (1). The weight of shaft (1) is approximately 50 kg (110 lb).
Note: Hold input shaft (2) away from shaft (1) for clearance.

2. Use the suitable lifting device to lift shaft (1) straight up out of transmission case.

Illustration 2 g00961151

3. Position shaft (1) on Tooling (C), as shown.

Illustration 3 g00961189

4. Use Tooling (D) in order to remove retaining ring (3). Remove thrust disc (4) .

Illustration 4 g00961435

5. Remove gear and hub assembly (5) .

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Illustration 5 g00961444

6. Use Tooling (G) in order to remove retaining ring (6) .

7. Separate hub (7) from gear (5). If necessary, remove sleeve bearing (8) .

Illustration 6 g00961455

8. Remove thrust disc (9) and retainer (10) .

Illustration 7 g00961468

9. Use Tooling (D) in order to remove retaining ring (11) .

Illustration 8 g00961492

10. Use a screwdriver to remove retaining ring (12) .

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Illustration 9 g00961507

Illustration 10 g00961630

11. Remove one end plate (13), clutch plates (14), and friction discs (15) .

Illustration 11 g00961639

Illustration 12 g00961647

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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12. Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) .

13. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (D) to
remove retaining ring (16). Remove Tooling (F) .

Illustration 13 g00961656

14. Remove balance piston assembly (17) .

Illustration 14 g00961678

15. Remove wave spring (18) .

Illustration 15 g00974947

16. Remove piston assembly (19) .

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Illustration 16 g00974948

17. Balance piston 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.

Illustration 17 g00974949

18. Reposition the shaft assembly, as shown. Remove three seal rings (20). Use Tooling (D) in order to remove retaining ring (21) .

Illustration 18 g00974950

19. Remove thrust disc (22) .

Illustration 19 g00974951

20. Remove washer (23) and gear (24) .

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Illustration 20 g00974953

21. Remove spacer assembly (25) .

Illustration 21 g00974954

22. Remove thrust disc (26), the gear, and hub assembly (27) .

Illustration 22 g00974955

23. Use Tooling (G) to remove retaining ring (28). Separate gear (27) from hub assembly (29). If necessary, remove sleeve bearing (30) .

Illustration 23 g00974956

24. Remove thrust disc (31) and retainer (32) .

Illustration 24 g00974957

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25. Use Tooling (D) in order to remove retaining ring (33) .

Illustration 25 g00974958

26. Use a screwdriver to remove retaining ring (34) .

Illustration 26 g00974959

Illustration 27 g00974960

27. Remove one end plate (35), clutch plates (36), and friction discs (37) .

Illustration 28 g00974961

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Illustration 29 g00974962

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.

28. Position the shaft assembly with the opening in retaining ring (38) in line with the opening in Tooling (F) .

29. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. The wave spring is not shown.

30. Use Tooling (D) in order to remove retaining ring (38) and remove Tooling (F) .

Illustration 30 g00974963

31. Remove balance piston assembly (39) .

Illustration 31 g00974964

32. Remove wave spring (40) .

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Illustration 32 g00974965

33. Remove piston assembly (41) .

Illustration 33 g00988356

34. Remove seal rings (41A) and (41B) from piston (41). Replace the seals, if necessary.

Illustration 34 g00974967

35. Attach Tooling (A) and a suitable lifting device to shaft assembly (42). The weight of shaft assembly (42) is approximately 41 kg (90 lb).
Remove shaft assembly (42).

Illustration 35 g00975447

36. Position shaft assembly (42) on Tooling (C), as shown.

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Illustration 36 g00975449

37. Use Tooling (D) in order to remove retaining ring (43) and remove thrust disc (44) .

Illustration 37 g00975452

38. Remove gear and hub assembly (45) .

Illustration 38 g00975454

39. Use Tooling (G) in order to remove retaining ring (46). Separate gear (45) from hub assembly (47). Remove sleeve bearing (48), if necessary.

Illustration 39 g00975456

40. Remove thrust disc (49) and retainer (50) .

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Illustration 40 g00975458

41. Use Tooling (D) in order to remove retaining ring (51) .

Illustration 41 g00975463

42. Use a screwdriver in order to remove retaining ring (52) .

Illustration 42 g00975467

43. Remove one end plate (53), clutch plates (54), and friction discs (55) .

Illustration 43 g00975553

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Illustration 44 g00975555

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.

44. Position the shaft so the opening in retaining ring (56) will line up with the opening in Tooling (F) .

45. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. Use Tooling (D) to remove the retaining ring (56).
Remove Tooling (F) .

Illustration 45 g00975558

46. Remove balance piston assembly (57) .

Illustration 46 g00975562

47. Remove wave spring (58) .

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Illustration 47 g00975564

48. Remove piston assembly (59) .

Illustration 48 g00988355

49. Remove seal rings (59A), and (59B) from piston (59). Replace the seals if it is necessary.

Illustration 49 g00975570

50. Position the shaft assembly with the opposite end upward, as shown. Remove three seal rings (60). Use Tooling (D) in order to remove
retaining ring (61) .

Illustration 50 g00975576

51. Remove thrust disc (62) and gear assembly (63) .

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Illustration 51 g00975578

52. Remove two sleeve bearings (64), if necessary.

Illustration 52 g00975579

53. Remove thrust disc (65) and retainer (66) .

Illustration 53 g00975584

54. Use Tooling (D) in order to remove retaining ring (68). Use a screwdriver in order to remove retaining ring (67) .

Illustration 54 g00975585

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Illustration 55 g00975587

55. Remove one end plate (69), clutch plates (70), and friction discs (71) .

Illustration 56 g00975588

Illustration 57 g00975810

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. Position the shaft assembly so the opening in retaining ring (72) will be in line with the opening in Tooling (F) .

57. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. The wave spring is not shown. Use Tooling (G) to
remove retaining ring (72). Remove Tooling (F) .

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Illustration 58 g00975811

58. Remove balance piston assembly (73) .

Illustration 59 g00975812

59. Remove wave spring (74) .

Illustration 60 g00975818

60. Remove piston assembly (75) .

Illustration 61 g01416908

61. Remove seal rings (76) and (77) from piston (75). Replace the seals if it is necessary.

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Illustration 62 g00975828

62. Remove input shaft group (78) .

Illustration 63 g00976174

63. Use a suitable press in order to remove carrier (80), bearing cone (81), and gear (82) from input shaft group (78) .

Illustration 64 g00975867

64. Remove seal ring (79) .

Illustration 65 g00976184

65. Invert shaft (78) in order to remove bearing cone (83), and gear (84) .

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Illustration 66 g01351399

66. Remove sensors (85) and (86) .

Illustration 67 g00976215

67. Attach Tooling (A) and a suitable lifting device to shaft assembly (87). The weight of shaft assembly is approximately 82 kg (180 lb). Remove
shaft assembly (87).

Illustration 68 g00976227

68. Position shaft assembly (87) on Tooling (C) .

Illustration 69 g00976228

69. Use Tooling (D) in order to remove retaining ring (88). Remove thrust disc (89) .

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Illustration 70 g00976229

70. Remove gear (90) .

Illustration 71 g00976230

71. Use Tooling (D) in order to remove retaining ring (91).

72. Separate hub assembly (92) from gear (90). Remove sleeve bearing (93), if it is necessary.

Illustration 72 g00976232

73. Remove thrust disc (94) and retainer (95) .

Illustration 73 g00977380

74. Use Tooling (D) in order to remove retaining ring (96) .

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Illustration 74 g00977422

75. Use a screwdriver in order to remove retaining ring (97) .

Illustration 75 g00977424

Illustration 76 g00977433

76. Remove one end plate (98), clutch plates (100), and disc assembly (99) .

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.

77. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring (not shown).

78. Use Tooling (D) in order to remove retaining ring (101). Release the pressure on the wave spring and remove Tooling (F) .

Illustration 78 g00977438

79. Remove balance seal assembly (102) .

Illustration 79 g00977441

80. Remove wave spring (103) .

Illustration 80 g00977444

81. Apply suitable air pressure to the passage in order to move piston assembly (104) upward. Remove piston assembly (104) from the shaft.

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Illustration 81 g00977446

82. Balance piston 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.

Illustration 82 g01351420

83. Attach a suitable lifting device and rotate shaft (87) to the opposite side. The weight of shaft (87) is approximately 45 kg (100 lb).

Illustration 83 g00977453

84. Remove seal rings (105) .

Illustration 84 g00977455

85. Remove thrust disc (106) .

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Illustration 85 g00979038

86. Use Tooling (D) in order to remove retaining ring (107) .

Illustration 86 g00979043

87. Remove gear (108) .

Illustration 87 g00979049

88. Remove thrust disc (109) .

Illustration 88 g00979054

89. Remove gear and hub assembly (110) .

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Illustration 89 g00979056

90. Use Tooling (G) in order to remove retaining ring (111) .

91. Separate hub assembly (112) from gear (110) .

92. If necessary, remove sleeve bearing (113) .

Illustration 90 g00979059

93. Remove thrust disc (114) and ring retainer (115) .

Illustration 91 g00979060

94. Use a screwdriver in order to remove retaining ring (116) .

Illustration 92 g00979063

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Illustration 93 g00979064

95. Remove one end plate (117), clutch plates (118), and friction discs (119) .

Illustration 94 g00979070

96. Use Tooling (G) in order to remove retaining ring (120) .

Illustration 95 g00979073

Illustration 96 g00979077

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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97. Position the shaft assembly so retaining ring (121) lines up with the opening on Tooling (H) .

98. 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) .

Illustration 97 g00979089

99. Remove balance piston (122) .

Illustration 98 g00979091

100. Remove wave spring (123) .

Illustration 99 g00979099

101. Remove piston assembly (124) .

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Illustration 100 g00984232

102. Balance piston assembly (122), wave spring (123), and piston assembly (124) upon removal. Check the lips on the seals for damage or wear.
Replace the seals if it is necessary.

Illustration 101 g01416910

103. Remove seals (125) and (126) from piston (124) .

Illustration 102 g00984239

104. Remove thrust disc (127) from transmission case (132) .

Illustration 103 g00984240

105. Remove bearings (128), (129), and (130) from transmission case (132) .

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Illustration 104 g00984243

106. Use Tooling (B) in order to remove bearing cone (131) from shaft (133) .

Illustration 105 g00984244

107. Rotate the transmission case. Remove bolt (134). Remove the yoke and brake drum (135) .

Illustration 106 g00984245

108. Remove bolts (136). Remove parking brake group (137) .

Illustration 107 g00984247

109. Remove bolts (138) .

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Illustration 108 g00984248

110. Use Tooling (L) to remove bearing cage (139) .

Illustration 109 g00984249

111. Remove shims (140), bearing cup (141), seal (142), and seal (143) from bearing cage (139) .

Illustration 110 g00984251

112. Remove shaft assembly (133) .

Illustration 111 g00984252

113. Use a suitable press to remove bearing cone (145) and gear (144) from shaft (133) .

Illustration 112 g00984253

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114. Remove bolts (147) and bearing cage (146) from transmission case (132) .

Illustration 113 g00984254

115. Remove bearing cup (150), seal (149), and shims (148) from bearing cage (146) .

Illustration 114 g00984255

116. Remove bolts (151) and remove cover (152) .

Illustration 115 g00984256

117. Remove suction screen (153) and magnetic screen (154) .

Illustration 116 g00960379

118. Remove bearings (156) and (157) from cover (155) .

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Illustration 117 g00960522

119. Remove bearing (158), bearing cup (159), and seal (160) from cover (155) .

JKM1-UP, JNJ1-UP, LKM1-UP, MCC1-UP, MJC1-UP

PPS-000017F8
2022/01/12
00:18:57+01:00
i02694355
© 2022 Caterpillar Inc.
Caterpillar:
Confidential Green

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