980G Wheel Loader Power Train Torque Converter - Disassemble - Heavy Duty Caterpillar

Disassembly Procedure

Start By:

1. Separate the torque converter from the transmission and from the output transfer gears. Refer to Disassembly and Assembly, "Torque Converter from Transmission, Output Transfer Gears - Separate" for the machine that is being serviced.

1. Place the torque converter housing assembly on wood blocks.
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   Illustration 1	g00503225

2. Remove eight bolts (1) and the washers from torque converter housing assembly (2).
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   Illustration 2	g00503286

3. Install Tooling (A) to torque converter housing assembly (2), as shown. Attach a hoist and suitable lifting chains to Tooling (A).

4. Use three 3/8" - 16 NC forcing screws (3) to loosen housing assembly (2) from the torque converter.

5. Use the hoist to remove housing assembly (2) from the torque converter. The weight of housing assembly (2) is 120 kg (265 lb).
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   Illustration 3	g00503287

6. Remove O-ring seal (4) from torque converter housing assembly (2).
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   Illustration 4	g00503288

7. Remove thirteen bolts (5) and the washers from pump adapter (6) and torque converter housing assembly (2).
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   Illustration 5	g00503289

8. Use three 3/8" - 16 NC forcing screws (7) to remove pump adapter (6) from torque converter housing assembly (2).
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   Illustration 6	g00503291

9. Remove bearing cup (8), O-ring seal (10) and shims (9) from pump adapter (6).
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   Illustration 7	g00503292

10. Remove pump drive gear (11) from torque converter housing assembly (2).
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    Illustration 8	g00503294

11. Use Tooling (B) to remove bearing cones (12) from each side to pump drive gear (11).
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    Illustration 9	g00503296

12. Use Tooling (C) to remove bearing cup (13) from torque converter housing assembly (2).
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    Illustration 10	g00503297

13. Remove bolt (14) and the washer from torque converter housing assembly (2).

14. Use 3/8" - 16 NC forcing screw (16) to push the shaft assembly out of torque converter housing assembly (2).

15. Remove idler gear (15) from torque converter housing assembly (2).
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    Illustration 11	g00503298

16. Remove O-ring seal (17) from shaft assembly (18).
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    Illustration 12	g00503299

17. Remove bearing cone (19), bearing cone spacer (20) and bearing cone (21) from idler gear (15).
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    Illustration 13	g00503301

18. Use Tooling (C) to remove bearing cup (22) from idler gear (15).
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    Illustration 14	g00503302

19. Remove bearing cup spacer (23) from idler gear (15).
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    Illustration 15	g00503308

20. Remove retaining ring (24) from idler gear (15).
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    Illustration 16	g00503309

21. Use Tooling (C) to remove bearing cup (25) from idler gear (15).
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    Illustration 17	g00503312

22. Remove two studs (26) from torque converter housing assembly (2).
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    Illustration 18	g00503314

23. Remove retaining ring (27) and bearing carrier (28) from the carrier assembly.
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    Illustration 19	g00503315

24. Remove O-ring seal (29) from bearing carrier (28).

25. Remove seal ring (30) from ring carrier (31).
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    Illustration 20	g00503316

26. Use Tooling (D) and a press to remove ring carrier (31) from bearing carrier (28).
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    Illustration 21	g00503318

27. Remove retaining ring (32) from bearing carrier (28).
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    Illustration 22	g00503319

28. Use Tooling (D) and a press to remove inner bearing (33) from bearing carrier (28).
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    Illustration 23	g00503321

29. Remove twelve bolts (34) and the washers from drive gear (35).

30. Remove drive gear (35) from the drive flange.
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    Illustration 24	g00503322

31. Use Tooling (E) and a press to remove the outer bearing race from drive gear (35).
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    Illustration 25	g00503344

32. Remove retaining ring (36) from drive gear (35).
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    Illustration 26	g00503345

33. Remove 36 bolts (37) from drive flange (38) and rotating housing (39).
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    Illustration 27	g00503347

34. Use two bolts (37) as forcing screws to remove drive flange (38) from rotating housing (39). The weight of drive flange (38) is 23 kg (51 lb).
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    Illustration 28	g00503348

35. Place the impeller hub on wood blocks.

36. Remove twelve bolts (40) from drive flange (38).
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    Illustration 29	g00503350

37. Remove drive flange (38) from the impeller hub and converter impeller (41).
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    Illustration 30	g00503351

38. Remove converter impeller (41) from impeller hub (42).
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    Illustration 31	g00503352

39. Remove two thrust bearing races (43) and the thrust bearing from the carrier assembly.
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    Illustration 32	g00503533

40. Remove carrier assembly (44) and the stator as a unit from rotating housing (39).
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    Illustration 33	g00503534

41. Remove snap ring (45).
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    Illustration 34	g00503535

42. Heat stator (46) and carrier assembly (44) as a unit to a minimum temperature of 121°C (250°F) for one hour. This will expand stator (46).

43. Remove stator (46) from carrier assembly (44).
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    Illustration 35	g00503536

44. Remove retainer ring (47) from stator (46).
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    Illustration 36	g00503537

45. Remove sleeve bearing (48) from carrier assembly (44).
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    Illustration 37	g00503538

46. Remove two thrust bearing races (49) and the thrust bearing from the hub.
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    Illustration 38	g00503539

47. Remove converter turbine (50) and turbine hub (51) as a unit from rotating housing (39).
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    Illustration 39	g00503540

48. Remove twenty bolts (52) and the washers from converter turbine (50).

49. Remove converter turbine (50) from turbine hub (51).
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    Illustration 40	g00503541

50. Remove retaining ring (53) from turbine hub (51).
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    Illustration 41	g00503542

51. Remove two thrust bearing races (54) and thrust bearing (55) from the cover assembly.
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    Illustration 42	g00503564

52. Remove eight bolts (56) and the washers from cover assembly (57).

53. Remove cover assembly (57) from rotating housing (39).

54. Remove ring seal (58) from rotating housing (39).
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    Illustration 43	g00503567

55. Remove sleeve bearing (59) from cover assembly (57).