986H Wheel Loader Differential and Bevel Gear - Disassemble Caterpillar


Differential and Bevel Gear - Disassemble
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1.1. Disassembly Procedure

Disassembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
1P-2420  Transmission Repair Stand 
439-3938  Link Bracket 
125-5723  Socket 
1H-3110  Bearing Puller Assembly 
9U-7399  Spanner 
9U-7398  Spanner 
1H-3110  Bearing Puller Assembly 
1H-3107 Puller Group 
1P-0520 Driver Group 

Start By:

  1. Remove the differential and bevel gear.


    Illustration 1g00667172

  1. Position the differential and bevel gear assembly on Tooling (A). The weight of the differential and bevel gear assembly is approximately 590 kg (1300 lb).


    Illustration 2g00667174

  2. Remove bolts (2) from pinion housing (1).


    Illustration 3g00667176

  3. Attach Tooling (B) and a suitable lifting device to pinion housing (1).

  4. Install two bolts (2) in the threaded holes of pinion housing (1). Tighten two bolts (2) evenly in order to separate pinion housing (1).


    Illustration 4g00667177

  5. Remove pinion housing (1). The weight of pinion housing (1) is approximately 132 kg (290 lb).


    Illustration 5g00667179

  6. Remove shim (3).

    Note: Steps 7 through 17 are used for the disassembly of the pinion housing.



    Illustration 6g00667181

  7. Remove O-ring seal (4) from pinion housing (1).


    Illustration 7g00667182

  8. Position pinion housing (1) onto suitable cribbing and remove Tooling (B). Remove bolts (5) and retainer (6).


    Illustration 8g00667183

  9. Remove O-ring seal (7) and lip seal (8) from retainer (6).


    Illustration 9g00667184


    Illustration 10g00667185

  10. Straighten the staked area of retaining nut (9).

  11. Use Tooling (C) in order to remove nut (9) from pinion shaft (10).


    Illustration 11g00667186

  12. Remove washer (11) from pinion shaft (10).


    Illustration 12g00667187


    Illustration 13g01151480

  13. Use a suitable press in order to press pinion shaft (10) from bearing cone (12). The weight of pinion shaft (10) is approximately 36 kg (80 lb).

  14. Remove bearing cone (12) from pinion housing (1).


    Illustration 14g00685135

  15. Use a suitable press and Tooling (D) in order to remove bearing cone (13) from pinion shaft (10).


    Illustration 15g01151482

  16. Remove bearing cup (14) from pinion housing (1).


    Illustration 16g01151484

  17. Reposition pinion housing (1). Remove bearing cup (15).

    Note: Steps 18 through 25 are for the removal of the differential from the carrier.



    Illustration 17g00685140

  18. Use a suitable lifting device in order to position the carrier and the differential assembly on Tooling (A). The combined weight of the carrier and the differential assembly is approximately 467 kg (1030 lb).


    Illustration 18g00685141

  19. Remove bolt (16) and lock (17) from bearing cap (18).

  20. Use Tooling (E) in order to remove adjusting ring (19).


    Illustration 19g00685143

  21. Remove bolt (20) and lock (21) from bearing cap (22).

  22. Use Tooling (F) in order to remove adjusting ring (23).


    Illustration 20g00685144

  23. Remove bolts (24) and bearing cap (22). Repeat for the opposite side.


    Illustration 21g00685145

  24. Remove bearing cup (25). Repeat for the opposite side.


    Illustration 22g00685146

  25. Remove differential and bevel gear (26) from carrier (27). The weight of differential and bevel gear (26) is approximately 272 kg (600 lb).

    Note: Steps 26 through 42 are used for the disassembly of the differential.



    Illustration 23g01151488


    Illustration 24g01151512

  26. Position differential and bevel gear (26) on suitable cribbing.

  27. Remove bolts (28). Use a suitable pry bar in order to install suitable cribbing between differential assembly (29) and bevel gear (30).

  28. Install Tooling (B) and a suitable lifting device to differential assembly (29).

  29. Remove differential assembly (29). The weight of differential assembly (29) is approximately 204 kg (450 lb). The weight of bevel gear (30) is approximately 59 kg (130 lb).


    Illustration 25g00685189

  30. Position differential assembly (29) onto suitable cribbing.

  31. Remove bolts (31). Do not remove two bolts (31). The two remaining bolts (31) should be 180 degrees from each other.


    Illustration 26g01151498


    Illustration 27g01151499

  32. Reposition differential assembly (29).

  33. Install Tooling (B) and a suitable lifting device to case assembly (32).

  34. Remove remaining two bolts (31).

  35. Remove case assembly (32). The weight of case assembly (32) is approximately 105 kg (230 lb).


    Illustration 28g01151501

  36. Use Tooling (G) in order to remove bearing cone (33) from case assembly (32).


    Illustration 29g03719170

  37. Reposition case assembly (32) and remove bolts (34) and thrust washer (35).


    Illustration 30g03719479

  38. Remove gear (36).


    Illustration 31g03719686

  39. Attach a suitable lifting device to the spider and pinion gear assembly (37). Remove the spider and pinion gear assembly (37) from case assembly (38). The weight of the spider and pinion gear assembly (37) is approximately 32 kg (70 lb).


    Illustration 32g03719783

  40. Remove spacer (41), pinion gear (40), and sleeve (39) from the spider and pinion gear assembly (37). Repeat this procedure for the remaining spider and pinion gear assemblies.


    Illustration 33g03719809

  41. Remove gear (42) from case assembly (38).


    Illustration 34g03719842

  42. Remove bolts (44) and thrust washer (43).


    Illustration 35g03719963

  43. Use Tooling (G) in order to remove bearing cone (45) from case assembly (38).

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