AD45B Underground Articulated Truck Power Train Caterpillar

Output Transfer Gears - Disassemble

Usage:

Disassembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0520	Driver Gp	1
B	138-7575	Link Bracket	4
C	138-7573	Link Bracket	2
D	1H-3107	Bearing Puller	1
	1H-3108	Push-Puller Leg	2
	1H-3110	Bearing Puller	1
	5F-7366	Screw	1
	5F-7351	Nut	1
	5F-7353	Washer	1
	6V-3160	Double Acting Cylinder	1
	4C-4865	Manual Hydraulic Pump	1
E	5F-7353	Washer	1
	6V-3160	Double Acting Cylinder	1
	4C-4865	Hand Hydraulic Pump	1
	1P-1839	Bearing Puller Adapter	1
	8S-6587	Adapter	1
	9S-5559	Stud	1
	1M-6756	Sleeve Assembly	1
	9H-3992	Head	1
	1P-9543	Nut	1
F	8B-7554	Bearing Cup Puller	1
	8B-7548	Bearing Puller	1
	8H-0684	Ratchet Wrench	1
G	8B-7548	Bearing Puller	1
	8B-7551	Bearing Puller	1
	9S-9154	Step Plate	1
	8H-0684	Ratchet Wrench	1
H	8B-7554	Bearing Cup Puller	1
	8B-7548	Push-Puller Tool Gp	1
	8B-7549	Puller Leg	2
	8H-0684	Ratchet Wrench	1
J	8B-7548	Push-Puller Tool Gp	1
	8B-7551	Bearing Puller	1
	5P-4170	Step Plate	1
	8H-0684	Ratchet Wrench	1

Start By:

Separate the output transfer gears from the transmission. Refer to Disassembly and Assembly, "Transmission from Output Transfer Gears - Separate".

Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.

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NOTICE

Failure to properly assemble parts or failure to follow established procedures can lead to damage of the parts and assembly. To avoid damage to parts, always identify and mark the parts so that they can be installed in the same location. Ensure that gear surfaces align. Never force parts during assembly.

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Illustration 1	g01094114

Remove bolt (1) and retainer (2) from yoke (3).
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Illustration 2 g01094116
Remove O-ring seal (4) and yoke (3).
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Illustration 3 g01094117
Remove eight bolts (5) from bearing cage (6).
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Illustration 4 g01094118
Use two bolts (5) as forcing screws in order to separate bearing cage (6) from transfer gear case (7).
Remove bearing cage (6) from transfer gear case (7).
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Illustration 5 g01094119
Remove lip seal (8) from bearing cage (6).
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Illustration 6 g01094120
Use Tooling (A) in order to remove bearing cup (9) (not shown) from bearing cage (6).
Remove O-ring seal (10) from bearing cage (6).
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Illustration 7 g01094121
Install Tooling (B) to transfer case. Attach suitable lifting chains and a hoist to Tooling (B).
Turn transfer gear case (7). The weight of transfer gear case (7) is approximately 520 kg (1150 lb).
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Illustration 8 g01094123
Remove bolt (11) and retainer (12) from yoke (13).
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Illustration 9 g01094125
Remove O-ring seal (14) and yoke (13).
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Illustration 10 g01094126

Note: The bolts are different lengths. Identify the bolts for installation purposes.
Remove 11 bolts (15) from bearing cage (16).
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Illustration 11 g01094128
Use two 3/8 inch bolts as forcing screws in order to separate bearing cage (16) from transfer gear case (7).
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Illustration 12 g01094131
Install Tooling (C) to bearing cage (16). Attach a suitable hoist and lifting chains to Tooling (C). The weight of bearing cage (16) is approximately 95 kg (210 lb).
Remove bearing cage (16) from transfer gear case (7).
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Illustration 13 g01094132
Remove O-ring seal (17) from bearing cage (16).
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Illustration 14 g01094133
Use Tooling (D) in order to remove shaft (18) from bearing cage (16).
Remove the spacer and gear (19) from shaft (18).
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Illustration 15 g01094134
Remove lip seal (20) from the bearing cage.
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Illustration 16 g01094135

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Illustration 17 g01094136
Turn bearing cage (16).
Remove six bolts (21) and retainer (22) from bearing cage (16).
Use Tooling (E) in order to remove two bearing cones (23) and one bearing cup from the bearing cage.
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Illustration 18 g01094137
Use Tooling (F) in order to remove the other bearing cup from bearing cage (16).
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Illustration 19 g01094138
Use Tooling (G) in order to remove bearing (24) from shaft (18).
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Illustration 20 g01061245
Remove nine bolts (25) and cover (26) from gear case cover (27).
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Illustration 21 g01094139
Remove O-ring seal (28) from cover (26).
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Illustration 22 g01061246
Remove eight bolts (29) from bearing cage (30).
Use two bolts (29) as forcing screws in order to separate bearing cage (30) from gear case cover (27).
Remove bearing cage (30) and shim pack (31) (not shown) from gear case cover (27).
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Illustration 23 g01094140
Use Tooling (H) in order to remove bearing cup (32) from bearing cage (30).
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Illustration 24 g01094141
Remove four nuts (33) from cover (34).
Remove cover (34) from bearing cage (35).
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Illustration 25 g01094142
Remove O-ring seal (36) from bearing cage (35).
Remove seven bolts (37) from bearing cage (35).
Use two bolts (37) as forcing bolts in order to separate bearing cage (35) from the gear case cover.
Remove bearing cage (35) and shim pack (38) (not shown) from the gear case cover.
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Illustration 26 g01094143
Remove O-ring seal (39) from bearing cage (35).
Use Tooling (H) in order to remove bearing cup (40) from bearing cage (35).
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Illustration 27 g01061247
Remove two bolts (41) and drain assembly (42) from transfer gear case (7).
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Illustration 28 g01061248
Remove eight bolts (43) from gear case cover (27).
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Illustration 29 g01061694
Install tooling (C) to gear case cover (27).
Attach suitable lifting chains and a hoist to Tooling (C). The weight of gear case cover (27) is approximately 45 kg (100 lb).
Remove gear case cover (27) from transfer gear case (7).
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Illustration 30 g01061251
Remove speed sensors (44) and (45) from transfer gear case (7).
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Illustration 31 g01061253
Attach a suitable lifting sling and a hoist to gear (46). The weight of gear (46) is approximately 39 kg (86 lb).
Remove gear (46) from the transfer gear case.
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Illustration 32 g01061254
Use Tooling (J) in order to remove two bearing cones (47) from gear (46).
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Illustration 33 g01061255
Attach a suitable lifting sling and a hoist to gear (48). The weight of gear (48) is approximately 29 kg (64 lb).
Remove gear (48) from the transfer gear case.
Use Tooling (F) (not shown) in order to remove the two bearing cups (49) and (50) from the transfer gear case.
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Illustration 34 g01061256
Remove two bearing cones (51) from gear (48).