986H Wheel Loader Differential and Bevel Gear - Disassemble Caterpillar

Disassembly Procedure

Start By:

1. Remove the differential and bevel gear.

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Illustration 1	g00667172

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).
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   Illustration 2	g00667174

2. Remove bolts (2) from pinion housing (1).
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   Illustration 3	g00667176

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).
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   Illustration 4	g00667177

5. Remove pinion housing (1). The weight of pinion housing (1) is approximately 132 kg (290 lb).
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   Illustration 5	g00667179

6. Remove shim (3).

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

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   Illustration 6	g00667181

7. Remove O-ring seal (4) from pinion housing (1).
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   Illustration 7	g00667182

8. Position pinion housing (1) onto suitable cribbing and remove Tooling (B). Remove bolts (5) and retainer (6).
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   Illustration 8	g00667183

9. Remove O-ring seal (7) and lip seal (8) from retainer (6).
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   Illustration 9	g00667184

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   Illustration 10	g00667185

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

11. Use Tooling (C) in order to remove nut (9) from pinion shaft (10).
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    Illustration 11	g00667186

12. Remove washer (11) from pinion shaft (10).
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    Illustration 12	g00667187

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    Illustration 13	g01151480

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).
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    Illustration 14	g00685135

15. Use a suitable press and Tooling (D) in order to remove bearing cone (13) from pinion shaft (10).
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    Illustration 15	g01151482

16. Remove bearing cup (14) from pinion housing (1).
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    Illustration 16	g01151484

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

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

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    Illustration 17	g00685140

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).
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    Illustration 18	g00685141

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

20. Use Tooling (E) in order to remove adjusting ring (19).
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    Illustration 19	g00685143

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

22. Use Tooling (F) in order to remove adjusting ring (23).
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    Illustration 20	g00685144

23. Remove bolts (24) and bearing cap (22). Repeat for the opposite side.
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    Illustration 21	g00685145

24. Remove bearing cup (25). Repeat for the opposite side.
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    Illustration 22	g00685146

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.

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    Illustration 23	g01151488

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    Illustration 24	g01151512

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).
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    Illustration 25	g00685189

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.
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    Illustration 26	g01151498

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    Illustration 27	g01151499

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).
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    Illustration 28	g01151501

36. Use Tooling (G) in order to remove bearing cone (33) from case assembly (32).
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    Illustration 29	g03719170

37. Reposition case assembly (32) and remove bolts (34) and thrust washer (35).
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    Illustration 30	g03719479

38. Remove gear (36).
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    Illustration 31	g03719686

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).
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    Illustration 32	g03719783

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.
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    Illustration 33	g03719809

41. Remove gear (42) from case assembly (38).
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    Illustration 34	g03719842

42. Remove bolts (44) and thrust washer (43).
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    Illustration 35	g03719963

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