784C and 785C Off-Highway Truck Power Train Caterpillar

Disassembly Procedure

Start By:

1. Remove the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Remove".

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.

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Illustration 1	g00493378

1. Remove bolts (1) that connect flywheel pilot (2) to clutch carrier (3).
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   Illustration 2	g00493428

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   Illustration 3	g00507749

2. Remove bolts (4), retainer (5), the shims, and the O-ring seal.

3. Remove bolts (6) that fasten clutch carrier (3) to housing (7).

   Note: If necessary, use 5/8 inch - 11 NC forcing bolts in order to loosen clutch carrier (3) from housing (7).

4. Attach Tooling (A) and a suitable lifting device to clutch carrier (3). Remove clutch carrier (3) from housing (7). The weight of clutch carrier (3) and the converter turbine as a unit is approximately 121 kg (267 lb).
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   Illustration 4	g00493460

5. Position clutch carrier (3), as shown. Use Tooling (B) in order to remove the converter turbine from clutch carrier (3). If necessary, remove pipe plug (8) and orifice plug (9) from clutch carrier (3).
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   Illustration 5	g00495384

6. Remove bolts (12) and split washers (11) from backing plate (10). Remove backing plate (10) from clutch carrier (3).
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   Illustration 6	g00493623

7. Remove friction discs (13) and clutch plates (14) from clutch carrier (3).
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   Illustration 7	g00493625

8. Remove lockup clutch piston (15) from clutch carrier (3).

   Note: Two 3/8 inch - 16 NC bolts may be installed in order to provide a lifting point for lockup clutch piston (15).

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   Illustration 8	g00493626

9. Remove seal ring (16) from lockup clutch piston (15). Remove seal ring (19) from clutch carrier (3).

10. Remove wear sleeve (17) and ball bearing (18) from clutch carrier (3).
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    Illustration 9	g01001804

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    Illustration 10	g00493639

11. Install Tooling (A) and a suitable lifting device to converter turbine (25). Remove converter turbine (25) from housing (7). The weight of converter turbine (25) is approximately 34 kg (75 lb).

12. Remove Tooling (A) and the suitable lifting device from converter turbine (25).

13. Remove seal ring (21) from ring carrier (22). Remove race (23) and ring carrier (22) from converter turbine (25).

14. Remove bolts (24) in order to remove clutch hub (20) from converter turbine (25).
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    Illustration 11	g00559462

15. Rotate converter turbine (25). Use prybars to remove turbine hub assembly (26) from converter turbine (25), as shown.
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    Illustration 12	g00494972

16. Remove thrust race (29) and sleeve (28) from turbine hub assembly (26).

17. Remove sleeve bearing (27) from turbine hub assembly (26).
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    Illustration 13	g00493753

18. Use Tooling (C) in order to remove retaining ring (30) from output shaft (31).
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    Illustration 14	g00493762

19. Remove converter stator (32) and thrust bearing (33).

    Note: When the converter stator is removed, the freewheel rollers may fall out of the roller cage. Locate all of the freewheel rollers. There are 22 freewheel rollers.

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    Illustration 15	g00494900

20. Use a screwdriver in order to remove retaining ring (35) from converter stator (32). Remove side plate (34) from converter stator (32).
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    Illustration 16	g00493794

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    Illustration 17	g00559448

21. Remove freewheel rollers (36) from roller cage (37).

22. Remove roller cage (37) from converter stator (32).

23. Remove springs (38) from roller cage (37).
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    Illustration 18	g00559423

24. Rotate converter stator (32). Remove side plate (39) from converter stator (32).

    Note: Side plate (39) is staked.

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    Illustration 19	g00559412

25. Rotate converter stator (32). Use a screwdriver in order to remove retaining ring (35) from converter stator (32).

26. Use Tooling (B) (not shown) and a suitable press in order to remove freewheel cam (40) from converter stator (32).
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    Illustration 20	g00493823

27. Attach Tooling (A) and a suitable lifting device onto housing (7). Remove housing (7) and converter impeller assembly (41) from output shaft (31). The weight of housing (7) and converter impeller assembly (41) as a unit is approximately 80 kg (176 lb).
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    Illustration 21	g00494001

28. Remove thrust bearing (42).
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    Illustration 22	g00495825

29. Remove bolts (43) in order to remove impeller hub assembly (44) from converter impeller assembly (41).

30. Remove hex socket screws (47) and the retaining washers. Remove wear sleeve (45) and thrust race (46) from impeller hub assembly (44).
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    Illustration 23	g00494017

31. Rotate housing (7). Place wood blocks under converter impeller assembly (41). Remove bolts (48) and the washers in order to remove converter impeller assembly (41) from housing (7).

    Note: If necessary, install four equally spaced bolts. Gently tap on the bolts with a soft faced hammer in order to remove the converter impeller assembly.

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    Illustration 24	g00494822

32. Remove bolts (50) from pump drive gear (49) in order to remove pump drive gear (49) from converter impeller assembly (41).
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    Illustration 25	g00494054

33. Use a brass drift in order to remove wear sleeve (51) from converter impeller assembly (41).
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    Illustration 26	g00494080

34. Remove bolts (52) and split washer (54) in order to remove freewheel race (53) from stator carrier (56).

35. Remove ring seals (55) from stator carrier (56).
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    Illustration 27	g00494123

36. Remove bolt (57), retainer (58) and the O-ring seal in order to remove yoke (59) from the output shaft.
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    Illustration 28	g00494141

37. Remove bolts (60) in order to remove fluid distributor (61) and the gasket from stator carrier (56).

38. Remove lip seal (62) from fluid distributor (61).

39. If necessary, remove O-ring plug (63) and the O-ring seal from fluid distributor (61).
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    Illustration 29	g00494681

40. Attach Tooling (E) and a suitable lifting device onto output shaft (31). Remove output shaft (31) from stator carrier (56). The weight of output shaft (31) is approximately 25 kg (55 lb).

41. Remove Tool (E) from output shaft (31).
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    Illustration 30	g00494202

42. Remove ring seals (64) from ring carrier (67). Remove ring seal (66) from ring carrier (65).

43. Remove ring carrier (65), ring carrier (67), and ball bearing (68) from output shaft (31).
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    Illustration 31	g00494747

44. Remove retaining ring (70) and inner bearing (69) from stator carrier (56).