988G Wheel Loader Power Train Torque Converter (Lockup) - Disassemble - Type 2 Caterpillar

Disassembly Procedure

Start By:

1. Remove the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Remove" for the machine that is being serviced.

2. Remove the transmission oil pump. Refer to Disassembly and Assembly, "Transmission Oil Pump - Remove" for the machine that is being serviced.

3. Remove the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Relief Valve (Torque Converter Outlet) - Remove" for the machine that is being serviced.

4. Remove the modulating valve for the torque converter impeller clutch. Refer to Disassembly and Assembly, "Modulating Valve (Torque Converter Impeller Clutch) - Remove" for the machine that is being serviced.

5. Remove the modulating valve for the torque converter lockup clutch. Refer to Disassembly and Assembly, "Modulating Valve (Torque Converter Lockup Clutch) - Remove" for the machine that is being serviced.

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Illustration 1	g00673844

1. Place the torque converter assembly on cribbing. The weight of the torque converter assembly is 545 kg (1200 lb).
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   Illustration 2	g00660841

2. Remove speed sensor (1).
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   Illustration 3	g00665406

3. Remove bolt (2) and retainer (3).
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   Illustration 4	g00665411

4. Remove O-ring seal (4) and yoke (5).
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   Illustration 5	g00665412

5. Remove eleven bolts (6) and the washers.
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   Illustration 6	g00665414

6. Install Tooling (A) to housing assembly.

7. Attach a suitable lifting device and lifting chains to Tooling (A).

8. Use M12 x 1.75 forcing screws in order to separate housing assembly from the torque converter.

9. Use the suitable lifting device in order to remove housing assembly. The weight of the housing assembly is 285 kg (630 lb).
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   Illustration 7	g00660846

10. Remove eight bolts (7) and retainer (8).
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    Illustration 8	g00660847

11. Remove seal (9) from retainer (8).
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    Illustration 9	g00660849

12. Remove gasket (10).

13. Remove O-ring seal (11) and (12).
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    Illustration 10	g00673879

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    Illustration 11	g00673880

14. Position torque converter assembly onto the side, as shown.

15. Remove six bolts (13) and cover (14).
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    Illustration 12	g00673881

16. Remove two bolts (15), retainer (16), and washer (17).
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    Illustration 13	g00673882

17. Use Tooling (B) in order to push the shaft out of the bearing.
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    Illustration 14	g00673883

18. Position torque converter assembly upright, as shown.

19. Install Tooling (C) to shaft assembly (18).

20. Attach a suitable lifting device and a sling to Tooling (C).

21. Use the suitable lifting device in order to remove shaft assembly (18). The weight of shaft assembly (18) is 17 kg (38 lb).
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    Illustration 15	g00673886

22. Use a suitable press in order to remove bearing (19) and seal carrier (20) from inner shaft (18).
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    Illustration 16	g01061064

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    Illustration 17	g01061071

23. Remove 36 bolts (21), and washers (22). Do not remove two bolts (25) at this time.
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    Illustration 18	g00673887

24. Install Tooling (D).

25. Attach a suitable lifting device and lifting slings to Tooling (D).

26. Use the suitable lifting device in order to remove carrier assembly (23). The weight of carrier assembly (23) is 132 kg (290 lb).
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    Illustration 19	g00673888

27. Place carrier assembly (23), as shown.

28. Remove stator (24).
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    Illustration 20	g01060995

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    Illustration 21	g01061000

29. Remove retaining ring (29) and plate (28) from stator (24). Remove ring (26) (not shown), and plate (27) (not shown) from the other side of stator (24).

30. Use a suitable press in order to remove adapter (30) from stator (24).
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    Illustration 22	g00674499

31. Remove spacer (33).
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    Illustration 23	g00674501

32. Remove bearing (34).

33. Remove the plate and the ring below bearing (34).
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    Illustration 24	g00674503

34. Remove retaining ring (35).
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    Illustration 25	g00674504

35. Use two persons in order to remove impeller (36). The weight of impeller (36) is 29 kg (65 lb).
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    Illustration 26	g00674505

36. Remove race (37) from impeller (36).
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    Illustration 27	g00674506

37. Remove twelve bolts (38) and the washers.

38. Remove impeller (36) from adapter assembly (39).
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    Illustration 28	g03389759

39. Remove plate (40a), bearing (40b), plate (40c), and ring (40d).
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    Illustration 29	g01061078

40. Remove two bolts (25) and plate (41).

    Note: Bolts (25) are on the underside of plate (41).

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    Illustration 30	g00674510

41. Remove two friction discs (42) and one wear plate.
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    Illustration 31	g00674512

42. Remove piston (43).
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    Illustration 32	g00674516

43. Remove seal (44) from piston (43).
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    Illustration 33	g00674514

44. Install Tooling (E) to housing assembly (45).

45. Attach a suitable lifting device and slings to housing assembly (45).

46. Use the suitable lifting device in order to remove housing assembly (45). The weight of housing assembly (45) is 45 kg (100 lb).
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    Illustration 34	g00674519

47. Remove twelve bolts (46) and gear (47) from housing assembly (45).
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    Illustration 35	g00674520

48. Remove race (48) from gear (47).
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    Illustration 36	g00674521

49. Remove eight bolts (49) and sleeve (50).
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    Illustration 37	g00674522

50. Remove seal (51) from sleeve (50).
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    Illustration 38	g00674523

51. Remove seal (52).

52. Remove two seals (53).

53. Remove retaining ring (54).
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    Illustration 39	g00674524

54. Use a hammer and a punch in order to remove pin (55).
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    Illustration 40	g00674721

55. Use Tooling (F) in order to remove ring carrier (56).
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    Illustration 41	g00674722

56. Use Tooling (G) in order to remove bearing (57).
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    Illustration 42	g00674723

57. Remove bearing (58).

58. Remove the plate and the ring below bearing (58).
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    Illustration 43	g00674725

59. Use appropriate equipment to turn the housing onto the opposite side.

60. Remove O-ring seal (59) and two plugs (60).
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    Illustration 44	g00674726

61. Use suitable cribbing in order to support the turbine and hub assembly. Place the cribbing inside the housing assembly.

62. Use Tooling (H) in order to remove the hub from bearing (61).
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    Illustration 45	g00674727

63. Remove bearing (61).
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    Illustration 46	g00674744

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    Illustration 47	g00674747

64. Remove 24 bolts (62) and hub (63) from turbine (64).

65. Remove clutch adapter (65).
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    Illustration 48	g01924533

66. Remove plate (66) and bearing (67).

67. Remove the plate and the ring below bearing (67).
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    Illustration 49	g01924775

68. Remove retaining ring (68) and plate (69).
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    Illustration 50	g01924777

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    Illustration 51	g01924895

69. Remove two wear plates (70) and two friction discs (71).
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    Illustration 52	g01924913

70. Remove piston (72).

    Note: It may be necessary to use shop air under pressure of 621 kPa (90 psi) to remove piston (72).

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    Illustration 53	g01925054

71. Remove seal (73) from piston (72).

    Note: The following steps are used for the removal and disassembly of the pump drives.

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    Illustration 54	g01925096

72. Remove seven bolts (74).
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    Illustration 55	g01925106

73. Install two forcing screws and Tooling (J).

74. Attach a suitable lifting device and lifting slings to Tooling (J).

75. Use the suitable lifting device in order to remove adapter (75). The weight of adapter (75) is 30 kg (65 lb).

    Note: If necessary, use forcing screws to separate adapter (75) from the housing.

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    Illustration 56	g01925114

76. Remove two O-ring seals (76) from adapter (75).
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    Illustration 57	g01925125

77. Remove race (77) and seal (78) from adapter (75).
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    Illustration 58	g01925633

78. Remove gear assembly (79).
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    Illustration 59	g01925655

79. Use Tooling (F) in order to remove bearing (80) from gear assembly (79).
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    Illustration 60	g01925696

80. Remove retaining ring (81) and adapter (82) from gear assembly (79).
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    Illustration 61	g01925716

81. Remove retaining ring (83) from adapter (82). Remove plate (84).
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    Illustration 62	g01925721

82. Use Tooling (F) in order to remove bearing (85) from gear assembly (79).
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    Illustration 63	g01925744

83. Remove shim pack (86) and race (87).
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    Illustration 64	g01925815

84. Remove three bolts (88) and cover (89).
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    Illustration 65	g01926035

85. Remove O-ring seal (90) from cover (89).
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    Illustration 66	g01926053

86. Remove bolt (91) and the washer.

87. Remove idler gear shaft (92).
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    Illustration 67	g03410576
    If equipped with this style lube adapter.

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    Illustration 68	g03410578
    If equipped with this style lube adapter.

88. Remove lube adapter (91a), (92b).
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    Illustration 69	g01926061

89. Remove idler gear assembly (93).
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    Illustration 70	g01926133

90. Remove two bearings (94) and ring (95) from idler gear assembly (93).
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    Illustration 71	g01926157

91. Remove four bolts (96) and block (97).
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    Illustration 72	g01926163

92. Remove five O-rings (98) and three plugs (99).

93. Repeat steps 72 through 92 in order to remove the remaining pump adapter.