980H Wheel Loader Power Train Transmission Planetary - Disassemble - Heavy Duty Caterpillar

Disassembly Procedure

Start By:

1. Separate the transmission and the output transfer gears. Refer to Disassembly and Assembly, "Transmission to Output Transfer Gears - Separate".

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	g01915294

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	g01886813

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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. Install 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 (12), and dowels (14) from manifold assembly.
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    Illustration 10	g01886816

14. Remove gear (15) from the carrier assembly.
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    Illustration 11	g01886818

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	g01886835

22. Use Tooling (F) to remove retaining ring (29) from the housing assembly.

23. Remove gear (28).

24. Remove O-ring seal (30) from the manifold assembly.
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    Illustration 16	g01886836

25. Remove bolts (31) that hold the manifold assembly to the clutch housing.
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    Illustration 17	g01886838

26. Attach Tooling (B) and a suitable lifting device to manifold assembly (32). The weight of manifold assembly (32) is approximately 72 kg (160 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	g01886841

29. Remove bolts (36) from the clutch housing.
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    Illustration 20	g01886843

30. Use Tooling (D) to hold the piston in the clutch housing (37). Attach Tooling (B) and a suitable lifting device to the clutch housing (37). The weight of clutch housing (37) is approximately 25 kg (55 lb).

31. Carefully remove clutch housing (37).

32. Remove springs (38).
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    Illustration 21	g01886845

33. Remove clutch piston (39) from the clutch housing.
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    Illustration 22	g01886846

34. Remove seals (40) and (41) from the clutch piston.
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    Illustration 23	g01886847

35. Remove friction discs (43), clutch plate (42) and dowels (44).
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    Illustration 24	g01886848

36. Remove retaining ring (45) from the shaft assembly.

37. Attach Tooling (B) and a suitable lifting device to clutch housing assembly (46). The weight of clutch housing (46) is approximately 45 kg (100 lb).

38. Carefully remove clutch housing (46).
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    Illustration 25	g01886849

39. Remove seal rings (48) from the ring carrier (47).

40. Check the condition of the ring carrier (47). If ring carrier (47) is worn or damaged, use new parts for replacement. If the ring carrier is not worn or damaged, DO NOT remove ring carrier (47). Use a hammer and a chisel in order to break the ring carrier. Remove the ring carrier and pin (49) from housing assembly.
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    Illustration 26	g01886850

41. Remove bolts (52) from the housing.

42. Remove ring gear (50) and gear (51).
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    Illustration 27	g01886852

43. Remove friction discs (53) and clutch plates (54) from the housing assembly.
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    Illustration 28	g01886853

44. Remove reaction plate (56) from housing assembly (55).
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    Illustration 29	g01886854

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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.

45. Use Tooling (H) and a suitable press in order to put force on plate (57) until spiral lockring (58) can be removed. Release the force. Remove the plate and three springs (59) from the housing.
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    Illustration 30	g01886856

46. Remove piston (60) from reaction plate (56).
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    Illustration 31	g01887775

47. Remove seals (61) and (62) from piston (60).
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    Illustration 32	g01886860

48. Use Tooling (D) to hold the piston inclutch housing (63). Attach Tooling (B) and a suitable lifting device to clutch housing (63). The weight of clutch housing (63) is approximately 39 kg (85 lb). Remove clutch housing (63).

49. Remove springs (64).
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    Illustration 33	g01886861

50. Remove piston (65) from housing assembly.
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    Illustration 34	g01888273

51. Remove seals (66) and (67) from the piston.
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    Illustration 35	g01886896

52. Remove friction discs (68) and clutch plates (69).
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    Illustration 36	g01886897

53. Use Tooling (E) in order to remove retaining ring (70) from the shaft assembly.

54. Attach Tooling (B) and a suitable lifting device to carrier (71). The weight of carrier (71) is approximately 26 kg (58 lb).
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    Illustration 37	g01886898

55. Use Tooling (E) to remove retaining ring (72) from hub (73). Remove hub (73) from the carrier.

56. Remove gear (74) from the carrier.
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    Illustration 38	g01886900

57. Remove spiral lockring (75). Remove bearing (76) from the carrier.
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    Illustration 39	g01888333

58. Remove spring pin (87) from the carrier.
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    Illustration 40	g01888354

59. Remove shaft (82), thrust discs (78) and (81), and gear (79). Remove bearing (80) from the gear (79). Remove pin (77) from shaft (82).

60. Repeat Steps 58 through 59 for the removal of the remaining gears.
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    Illustration 41	g01886934

61. Remove gear (83) from the shaft assembly.
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    Illustration 42	g01886953

62. Remove bolts (86) from clutch housing (84).

63. Use Tooling (D) to hold the piston in clutch housing (84). Attach Tooling (B) and a suitable lifting device to clutch housing (84). The weight of clutch housing (84) is approximately 44 kg (97 lb).

64. Remove clutch housing (84), springs (85), and dowels (87).
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    Illustration 43	g01887014

65. Remove piston (88) from the clutch housing.
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    Illustration 44	g01887093

66. Remove seals (89) and (90) from the clutch piston.
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    Illustration 45	g01887195

67. Remove friction discs (91) and clutch plates (92).
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    Illustration 46	g01887197

68. Remove gear assembly (93) and plate assembly (94) from the clutch housing.
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    Illustration 47	g01887198

69. Remove friction plates (95) and clutch plates (96).
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    Illustration 48	g01887199

70. Attach Tooling (C) and a suitable lifting device to output shaft assembly (97). The weight of output shaft assembly (97) and the carrier is approximately 90 kg (200 lb).

71. Remove the retaining ring that holds output shaft assembly (97) in the bearing on the bottom of the clutch housing.

72. Remove output shaft assembly (97) and the carrier from the clutch housing.

73. Place output shaft assembly (97) on suitable blocks.
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    Illustration 49	g01887200

74. Use Tooling (E) to remove retaining ring (98).
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    Illustration 50	g01887201

75. Use a soft hammer to remove shaft assembly (99) from the bearing in the carrier.
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    Illustration 51	g01887202

76. Remove carrier assembly (100) from the shaft assembly.
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    Illustration 52	g01887203

77. Remove seals (103) and (104) from the carrier assembly.

78. Remove spiral lockring (101).

79. Use Tooling (G) to remove bearing (102).
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    Illustration 53	g01887207

80. Use a hammer and a punch to push spring pin (105) from the carrier assembly.
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    Illustration 54	g01888539

81. Remove shaft (110), thrust discs (106) and (109), and gear (107). Remove bearing (108) from gear (107). Remove pin (105) from shaft (110).

82. Repeat Steps 80 and 81 for the remaining gears.
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    Illustration 55	g01887209

83. Remove spacer (112) and gear (111) from the shaft assembly.
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    Illustration 56	g01887210

84. Put the shaft assembly on suitable blocks, as shown. Use two people to remove carrier assembly (113) from the shaft assembly. The weight of carrier assembly (113) is approximately 32 kg (70 lb).
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    Illustration 57	g01887212

85. Put the carrier assembly on a suitable block, as shown. Use a screwdriver to compress the retainer ring. Remove gear (114) from the carrier assembly. Remove retaining ring (115).
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    Illustration 58	g01887213

86. Remove spiral lockring (116). Use Tooling (G) to remove bearing (117) from the carrier. Remove seal rings (118).
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    Illustration 59	g01887215

87. Use a hammer and a punch to push spring pin (119) from the carrier assembly.
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    Illustration 60	g01887216

88. Remove shaft (128), thrust discs (120), (123), (124) and (127), and gears (122) and (126). Remove bearings (121) and (125) from the gears. Remove pin (119) from shaft (128).

89. Repeat Steps 87 and 88 for the remaining gears.
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    Illustration 61	g01887217

90. Remove gear (129) from the shaft assembly.

91. Remove seals (130) and (131) from the seal carrier.
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    Illustration 62	g01887218

92. Remove spiral lockring (132) from the shaft assembly.
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    Illustration 63	g01887219

93. Put shaft assembly on suitable blocks, as shown. Use a soft hammer to strike shaft assembly (134) until the bearing is removed from shaft assembly (133).
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    Illustration 64	g01889333

94. Remove retaining ring (135) from the shaft assembly. Remove bearing (136).
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    Illustration 65	g01887221

95. Use Tooling (H) and a suitable press to remove seal carrier (137) from the shaft assembly.
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    Illustration 66	g01887222

96. Use Tooling (L) to remove bearing (138) from the shaft assembly.
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    Illustration 67	g01887223

97. Remove gear (139) from the clutch housing.

98. Remove piston (140) from the clutch housing.
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    Illustration 68	g01887224

99. Remove seals (141) and (142) from the piston.
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    Illustration 69	g01887226

100. Remove spiral lockring (143). Use Tooling (G) to remove bearing (144) from the housing.