Transmission Planetary - Disassemble - Standard
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980G Wheel Loader Power Train
[SENR5877]
980G Wheel Loader Power Train
Torque Converter - Assemble - Heavy duty
980G Wheel Loader Power Train
Transmission Planetary - Assemble - Standard
POWER TRAIN
TRANSMISSION GP
980G Wheel Loader Power Train
Torque Converter from Transmission, Output Transfer Gears - Separate
980G Wheel Loader Power Train
Torque Converter to Transmission, Output Transfer Gears - Connect
980G Wheel Loader Power Train
Output Transfer Gears from Transmission, Torque Converter - Separate
980G Wheel Loader Power Train
Output Transfer Gears - Disassemble
980G Wheel Loader Power Train
Output Transfer Gears - Assemble
980G Wheel Loader Power Train
Transmission Planetary - Disassemble
980G Wheel Loader Power Train
Transmission Planetary - Assemble
1.1. Disassembly Procedure
Disassembly Procedure
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| Required Tools | |||
|---|---|---|---|
| Tool | Part Number | Part Description | Qty |
| A | 1P-2420 | Transmission Repair Stand | 1 |
| B | 138-7573 | Link Bracket | 3 |
| C | 1P-7407 | Eyebolt | 2 |
| D | FT-0833 | Clamp | 3 |
| E | 1P-1863 | Retaining Ring Pliers | 1 |
| F | 5P-5197 | External Pliers | 1 |
| G | 1P-0520 | Driver Group | 1 |
| H | 2P-2345 | Spanner Wrench | 1 |
| J | 2P-8312 | External Pliers | 1 |
| K | FT-0947 | Spring Compressor | 2 |
| L | 2D-1201 | Eyebolt | 2 |
| M | 1P-7407 | Eyebolt | 3 |
| N | 1P-1861 | Internal Pliers | 1 |
Start By:
- Separate the transmission from the torque converter. Refer to Disassembly and Assembly, "Transmission from Torque Converter - Separate" for the machine that is being serviced.
- Remove the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Remove" for the machine that is being serviced.
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.
- Fasten Tooling (B) to the transmission, as shown. Attach a hoist and suitable lifting chains to Tooling (B) .
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| Illustration 1 | g00509346 |
- Place the transmission on Tooling (A). The weight of the transmission is 565 kg (1250 lb).
- Fasten Tooling (B) to planetary group (1). Attach a hoist and suitable lifting chains to Tooling (B) .
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| Illustration 2 | g00509347 |
- Remove two bolts (3) from transmission case (2) and planetary group (1) .
- Install two 1/2" - 13 NC forcing screws (4) in transmission case (2) .
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| Illustration 3 | g00509348 |
- Use the hoist and forcing screws (4) to remove planetary group (1) from transmission case (2). The weight of the planetary group is 425 kg (935 lb).
- Use Tooling (B) and a hoist to remove transmission case (2) from Tooling (A). The weight of the transmission case is 143 kg (315 lb).
- Place planetary group (1) on Tooling (A). Fasten planetary group (1) to Tooling (A) with suitable bolts, washers and nuts.
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| Illustration 4 | g00509349 |
- Remove two O-ring seals (5) and O-ring seal (6) from manifold assembly (7) .
Note: Put alignment marks across the clutch housings for assembly purposes.
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| Illustration 5 | g00509350 |
- Remove eighteen bolts (8) and the washers from No. 6 clutch housing (9) .
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| Illustration 6 | g00509351 |
- Use Tooling (D) to hold clutch piston (10) in No. 6 clutch housing (9) .
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| Illustration 7 | g00509352 |
- Install Tooling (C) on No. 6 clutch housing (9). Attach a hoist and suitable lifting chains to Tooling (C) .
- Carefully remove No. 6 clutch housing (9) from manifold assembly (7). The weight of No. 6 clutch housing (9) is 29 kg (64 lb).
- Remove clutch piston (10) from No. 6 clutch housing (9) .
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| Illustration 8 | g00509354 |
- Remove seal rings (11) and (12) from clutch piston (10) .
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| Illustration 9 | g00509355 |
- Remove six dowels (13) and twelve springs (14) from manifold assembly (7) .
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| Illustration 10 | g00509356 |
- Remove three friction discs (15) and two clutch plates (16) from manifold assembly (7) .
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| Illustration 11 | g00509358 |
- Remove gear (17) from manifold assembly (7) .
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| Illustration 12 | g00509359 |
- Use Tooling (E) to remove retaining ring (18) from output shaft assembly (19) .
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| Illustration 13 | g00509361 |
- Remove carrier assembly (20) from manifold assembly (7) .
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| Illustration 14 | g00509362 |
- Use a small drift to bend four locks (21) off eight bolts (22). Remove bolts (22), locks (21) and slinger (23) from carrier assembly (20) .
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| Illustration 15 | g00509364 |
- Remove gasket (24) from carrier assembly (20) .
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| Illustration 16 | g00509365 |
- Use a hammer and a punch to push spring pin (25) in planetary shaft (26) .
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| Illustration 17 | g00509388 |
- Remove planetary shaft (26), thrust disc (27), planetary gear (29) and thrust disc (31) from carrier assembly (20) .
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| Illustration 18 | g00509389 |
- Remove bearings (28) and (30) from planetary gear (29) .
- Remove spring pin (25) from planetary shaft (26) .
- Repeat Steps 23 through 26 for the removal of the other three planetary gears.
- Use Tooling (F) to remove retaining ring (32) from housing assembly (33) .
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| Illustration 19 | g00509390 |
- Remove sun gear (34) from housing assembly (33) .
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| Illustration 20 | g00509394 |
- Use Tooling (F) to remove retaining ring (35) from housing assembly (33) .
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| Illustration 21 | g00509395 |
Note: Housing assembly (33) will drop a small amount in manifold assembly (7) after retaining ring (35) has been removed.
- Remove ten bolts (36) and the washers from manifold assembly (7) .
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| Illustration 22 | g00509396 |
- Fasten Tooling (C) to manifold assembly (7), as shown. Attach a hoist and suitable lifting chains to Tooling (C) .
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| Illustration 23 | g00509397 |
- Use the hoist to carefully remove manifold assembly (7) from No. 3 and No. 4 clutch housing (37). The weight of the manifold assembly is 88 kg (194 lb).
- Use Tooling (F) to remove retaining ring (38) from bearing (39) and manifold assembly (7) .
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| Illustration 24 | g00509400 |
- Turn manifold assembly (7) to the opposite side. Remove dowel (40) and O-ring seal (41) .
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| Illustration 25 | g00509401 |
- Use Tooling (G) to remove bearing (39) from manifold assembly (7) .
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| Illustration 26 | g00509402 |
- Remove ten springs (43) from clutch piston (62) .
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| Illustration 27 | g00509403 |
- Use a screwdriver to remove retaining ring (44) from the groove of ring gear (45) .
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| Illustration 28 | g00509404 |
- Remove O-ring seal (46) from housing assembly (33) .
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| Illustration 29 | g00509405 |
- Remove housing assembly (33) from ring gear (45) .
- Place housing assembly (33) in a suitable press, as shown. Use Tooling (H) to compress three disc springs (47) in housing assembly (33) .
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| Illustration 30 | g00509407 |
- Use Tooling (J) to remove retaining ring (48) from housing assembly (33) .
- Remove retainer plate (49) and three disc springs (47) from housing assembly (33) .
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| Illustration 31 | g00509409 |
- Remove clutch piston (50) from housing assembly (33) .
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| Illustration 32 | g00509410 |
- Remove seal rings (51) and (52) from clutch piston (50) .
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| Illustration 33 | g00509411 |
- Remove two seal rings (53) from ring carrier (54) .
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| Illustration 34 | g00509412 |
- Check the condition of ring carrier (54). If ring carrier (54) is worn or damaged, use new parts for replacement. If ring carrier (54) is not worn or damaged, DO NOT remove the ring carrier. Use a hammer and a chisel in order to break ring carrier (54). Remove ring carrier (54) and dowel (55) from housing assembly (33) .
- Remove four friction discs (56) and three clutch plates (57) from ring gear (45) .
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| Illustration 35 | g00509413 |
- Remove reaction plate (58) from ring gear (45) .
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| Illustration 36 | g00509415 |
- Remove ring gear (45) from No. 3 and No. 4 clutch housing (37) .
- Remove two friction discs (59) and one clutch plate (60) from No. 3 and No. 4 clutch housing (37) .
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| Illustration 37 | g00509416 |
- Remove five dowels (61) from No. 3 and No. 4 clutch housing (37) .
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| Illustration 38 | g00509417 |
- Use Tooling (K) to hold two clutch pistons (62) and (63) in No. 3 and No. 4 clutch housing (37), as shown.
- Install Tooling (L) in No. 3 and No. 4 clutch housing (37). Attach a hoist and suitable lifting chains to Tooling (L).
- Use the hoist to carefully remove No. 3 and No. 4 clutch housing (37) from No. 2 clutch housing (64). The weight of No. 3 and No. 4 clutch housing (37) is 52 kg (115 lb).
- Remove clutch piston (62) from No. 3 and No. 4 clutch housing (37) .
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| Illustration 39 | g00509418 |
- Remove seal rings (65) and (66) from clutch piston (62) .
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| Illustration 40 | g00509419 |
- Turn No. 3 and No. 4 clutch housing (37) to the opposite side. Remove clutch piston (63) from No. 3 and No. 4 clutch housing (37) .
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| Illustration 41 | g00509420 |
- Remove seal rings (67) and (68) from clutch piston (63) .
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| Illustration 42 | g00509421 |
- Remove ten bolt dampers (69) and two dowels (70) from both sides of No. 3 and No. 4 clutch housing (37) .
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| Illustration 43 | g00509423 |
- Remove ten springs (71) from No. 2 clutch housing (64) .
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| Illustration 44 | g00509425 |
- Remove three friction discs (72) and two clutch plates (73) from No. 2 clutch housing (64) .
- Use Tooling (E) to remove retaining ring (74) from output shaft (19) .
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| Illustration 45 | g00509427 |
- Remove clutch hub (75) from carrier assembly (76) .
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| Illustration 46 | g00509429 |
- Remove carrier assembly (76) and ring gear (77) as a unit from No. 2 clutch housing (64) .
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| Illustration 47 | g00509430 |
- Remove sun gear (78) from carrier assembly (76) .
- Use several small steel rods (79) (2.79 mm (.110 inch) diameter and one pointed tip) to compress the lock ring that holds carrier assembly (76) to ring gear (77) .
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| Illustration 48 | g00509431 |
- Remove carrier assembly (76) from ring gear (77) .
- Remove lock ring (80) from carrier assembly (76) .
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| Illustration 49 | g00509432 |
- Use a hammer and a punch to push spring pin (81) in planetary shaft (82) .
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| Illustration 50 | g00509433 |
- Remove planetary shaft (82), thrust disc (83), planetary gear (85) and thrust disc (86) from carrier assembly (76) .
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| Illustration 51 | g00509434 |
- Remove bearing (84) from planetary gear (85) .
- Remove spring pin (81) from planetary shaft (82) .
- Repeat Steps 70 through 73 for the removal of the other two planetary gears.
- Use a screwdriver to remove retaining ring (87) from bearing (88) and carrier assembly (76) .
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| Illustration 52 | g00509435 |
- Place carrier assembly (76) in a suitable press, as shown. Use Tooling (G) to remove bearing (88) from carrier assembly (76) .
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| Illustration 53 | g00509436 |
- Remove two bolts (89) from No. 2 clutch assembly (64) and No. 1 clutch assembly (90) .
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| Illustration 54 | g00509437 |
- Use Tooling (D) to hold clutch piston (91) in No. 2 clutch housing (64) .
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| Illustration 55 | g00509438 |
- Fasten Tooling (L) to No. 2 clutch housing (64). Attach a hoist and suitable lifting chains to Tooling (L) .
- Carefully remove No. 2 clutch housing (64) from plate assembly (92). The weight of No. 2 clutch housing (64) is 27 kg (60 lb).
- Remove clutch piston (91) from No. 2 clutch housing (64) .
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| Illustration 56 | g00509439 |
- Remove seal rings (93) and (94) from clutch piston (91) .
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| Illustration 57 | g00509440 |
- Remove five dowels (95) and ten springs (96) from plate assembly (92) .
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| Illustration 58 | g00509441 |
- Remove five friction discs (97) and four clutch plates (98) from plate assembly (92) .
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| Illustration 59 | g00509442 |
- Remove ring gear (99) from plate assembly (92) .
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| Illustration 60 | g00509444 |
- Use a screwdriver to remove retaining ring (100) from output shaft assembly (19) and carrier assembly (101) .
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| Illustration 61 | g00509445 |
- Remove output shaft assembly (19) from carrier assembly (101) .
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| Illustration 62 | g00509446 |
- Remove O-ring seal (102) from output shaft assembly (19) .
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| Illustration 63 | g00509447 |
- Remove sleeve bearings (103) and (104) from each end of output shaft assembly (19) .
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| Illustration 64 | g00509448 |
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| Illustration 65 | g00509450 |
- Use Tooling (E) to remove retaining ring (105) from output shaft assembly (19) .
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| Illustration 66 | g00509451 |
- Remove sun gear (106) from output shaft assembly (19) .
- Place output shaft assembly (19) in a suitable press, as shown. Use Tooling (G) to remove bearing (107) from output shaft assembly (19) .
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| Illustration 67 | g00509452 |
- Use Tooling (E) to remove retaining ring (108) from input shaft assembly (109) .
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| Illustration 68 | g00509453 |
- Remove carrier assembly (101) from No. 1 clutch housing (90) .
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| Illustration 69 | g00509455 |
- Remove sun gear (110) from carrier assembly (101) .
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| Illustration 70 | g00509456 |
- Place a small block under carrier assembly (101) .
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| Illustration 71 | g00509457 |
- Use several small steel rods (111) (3.18 mm (.125 inch) diameter and one pointed tip) to compress the lock ring that holds carrier assembly (101) to ring gear (112) .
- Remove carrier assembly (101) from ring gear (112) .
- Remove lock ring (113) from carrier assembly (101) .
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| Illustration 72 | g00509458 |
- Use a hammer and a punch to push spring pin (114) in planetary shaft (115) .
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| Illustration 73 | g00509459 |
- Remove planetary shaft (115), thrust disc (116), planetary gear (118), thrust disc (119), thrust disc (120), planetary gear (122) and thrust disc (123) from carrier assembly (101) .
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| Illustration 74 | g00509460 |
- Remove bearings (117) and (121) from planetary gears (118) and (122) .
- Remove spring pin (114) from planetary shaft (115) .
- Repeat Steps 100 through 103 for the removal of the other three planetary gears.
- Use a screwdriver to remove retaining ring (124) from bearing (125) and carrier assembly (101) .
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| Illustration 75 | g00509461 |
- Place carrier assembly (101) in a suitable press, as shown. Use Tooling (G) to remove bearing (125) from carrier assembly (101) .
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| Illustration 76 | g00509462 |
- Remove seal ring (126) from carrier assembly (101) .
- Remove plate assembly (92) from No. 1 clutch housing (90) .
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| Illustration 77 | g00509463 |
- Remove two dowel pins (127) from plate assembly (92) .
- Remove five friction discs (128) and four clutch plates (129) from No. 1 clutch housing (90) .
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| Illustration 78 | g00509465 |
- Remove sun gear (130) from input shaft assembly (109) .
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| Illustration 79 | g00509486 |
- Remove O-ring seal (131) from sun gear (130) .
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| Illustration 80 | g00509487 |
- Fasten Tooling (M) to No. 1 clutch housing (90). Attach a hoist and suitable lifting chains to Tooling (M) .
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| Illustration 81 | g00509488 |
- Use Tooling (E) to remove retaining ring (132) from input shaft assembly (109) .
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| Illustration 82 | g00509489 |
- Slightly lift No. 1 clutch housing (90). Use a soft faced hammer to push shaft assembly (109) out of No. 1 clutch housing (90) .
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| Illustration 83 | g00509490 |
- Remove metal seal rings (133) and (134) from carrier assembly (135) .
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| Illustration 84 | g00509491 |
- Use a screwdriver to remove retaining ring (136) from input shaft assembly (109) and carrier assembly (135) .
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| Illustration 85 | g00509493 |
- Remove input shaft assembly (109) from carrier assembly (135) .
- Use Tooling (J) to remove retaining ring (137) from input shaft assembly (109) .
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| Illustration 86 | g00509494 |
- Remove bearing (141), O-ring seal (140), carrier (138) and ring (139) from input shaft assembly (109) .
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| Illustration 87 | g00509495 |
- Use several small steel rods (142) (2.79 mm (.110 inch) diameter and one pointed tip) to compress the lock ring that holds carrier assembly (135) to ring gear (143) .
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| Illustration 88 | g00509497 |
- Remove carrier assembly (135) from ring gear (143) .
- Remove lock ring (144) from carrier assembly (135) .
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| Illustration 89 | g00509498 |
- Use a hammer and a punch to push spring pin (145) in planetary shaft (146) .
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| Illustration 90 | g00509499 |
- Remove planetary shaft (146), thrust disc (147), planetary gear (149) and thrust disc (150) from carrier assembly (135) .
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| Illustration 91 | g00509500 |
- Remove bearing (149) from planetary gear (150) .
- Remove spring pin (146) from planetary shaft (147) .
- Repeat Steps 123 through 127 for the removal of the other three planetary gears.
- Remove clutch piston (152) from No. 1 clutch housing (91) .
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| Illustration 92 | g00509501 |
- Remove seal rings (153) and (154) from clutch piston (152) .
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| Illustration 93 | g00509502 |
- Use Tooling (N) to remove retaining ring (155) from bearing (156) and No. 1 clutch housing (91) .
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| Illustration 94 | g00509503 |
- Place No. 1 clutch housing (91) in a suitable press. Use Tooling (G) to remove bearing (156) from No. 1 clutch housing (91) .
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| Illustration 95 | g00509504 |
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