Transmission Planetary - Disassemble
Disassembly Procedure
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| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 439-3939 | Link Bracket | 2 |
| B | 439-3938 | Link Bracket | 2 |
| C | 1P-2420 | Repair Stand for Transmission | 1 |
| D | 1P-0520 | Driver Group | 1 |
| E | 2D-1201 | Eyebolt | 1 |
| F | 5B-4274 | Bolt | 2 |
Start By:
- Remove the transmission and transfer gears from the truck. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Remove".
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| NOTICE |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
- Use a suitable lifting device in order to position transmission and transfer gears (1) onto a suitable repair stand. The weight of transmission and transfer gears (1) is approximately 2132 kg (4700 lb).
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| Illustration 1 | g01626990 |
- Remove guard (2) .
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| Illustration 2 | g01626991 |
- Remove cover (3) and the gasket. Remove cover (4) and the gasket.
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| Illustration 3 | g01626992 |
- Remove bolts (5) in order to remove manifold assembly (6) .
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| Illustration 4 | g01626994 |
- Remove sleeves (7) . Remove O-ring seals (8) .
Note: Note the location of sleeves (7) for installation purposes.
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| Illustration 5 | g01626996 |
- Remove O-ring seals (9) from sleeve (7) . Repeat this step for the remaining sleeves (7) .
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| Illustration 6 | g01626998 |
- Remove retaining ring (10) . Remove coupling assembly (11) .
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| Illustration 7 | g01626999 |
- Remove flanges (12) .
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| Illustration 8 | g01627002 |
- Remove O-ring seal (13) . Remove sleeve (14) . Remove O-ring seals (15) . Repeat this step for the remaining flange (12) .
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| Illustration 9 | g01627003 |
- Remove bolts (16) from control valve (17) .
Note: Note the location of bolts (16) for installation purposes.
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| Illustration 10 | g01627004 |
- Use Tooling (A) and a suitable lifting device in order to remove control valve (17) . The weight of control valve (17) is approximately 64 kg (141 lb).
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| Illustration 11 | g01627006 |
- Use Tooling (B) and a suitable lifting device in order to position transmission and transfer gears (1) onto Tooling (C) . The weight of transmission and transfer gears (1) is approximately 2132 kg (4700 lb).
Note: Use four suitable bolts in order to secure transmission and transfer gears (1) to Tooling (C) .
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| Illustration 12 | g01627007 |
- Remove magnetic screen assembly (18) .
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| Illustration 13 | g01627011 |
- Remove O-ring seals (19) .
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| Illustration 14 | g01627014 |
- Remove nuts (20) and covers (21) .
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| Illustration 15 | g01627026 |
- Remove O-ring seals (22) . Remove wave washers (23) .
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| Illustration 16 | g01627032 |
- Remove suction screens (24) and tube assemblies (25) .
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| Illustration 17 | g01627034 |
- Remove tube assembly (25) from suction screen (24) . Repeat this step for the remaining suction screen (24) .
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| Illustration 18 | g01627036 |
- Remove magnets (26) from tube assembly (25) . Repeat for the remaining screen tube assembly (25) .
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| Illustration 19 | g01627039 |
- Attach Tooling (A) and a suitable lifting device onto transmission and transfer gears (1) . The weight of transmission and transfer gears (1) is approximately 2132 kg (4700 lb).
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| Illustration 20 | g01627044 |
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Personal injury or death can occur from heavy components falling during removal or installation. Properly support the component with a suitable lifting device during removal or installation. |
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- Remove bolts (27) .
- Remove bolts (28) .
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| Illustration 21 | g01627054 |
- Remove transmission case (29) from the transfer gear case. The weight of transmission case (29) is approximately 318 kg (700 lb).
- Remove bolts (30) . Use Tooling (F) in order to remove drive adapter (31) .
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| Illustration 22 | g01627059 |
- Remove retaining ring (32) . Remove bearing (33) .
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| Illustration 23 | g01627061 |
- Remove bolts (34) . Remove baffle (35) .
- Remove thrust buttons (35A) . Use Tooling (B) in order to remove end housing (36) . The weight of end housing (36) is approximately 45 kg (100 lb).
Note: Note the orientation of thrust buttons (35A) for installation purposes.
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| Illustration 24 | g03733328 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Remove springs (37) and springs (38) . Remove pins (39) and pins (40) .
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| Illustration 25 | g01668302 |
- Remove discs (41) and plates (42) .
Note: Note the quantity and the order of discs (41) and plates (42) .
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| Illustration 26 | g01627066 |
- Remove bolts (43) . Remove ring (44) and oil slinger (45) .
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| Illustration 27 | g01627069 |
- Remove O-ring seal (46) . Use Tooling (B) and a suitable lifting device in order to remove planetary carrier (47) . The weight of planetary carrier (47) is approximately 113 kg (250 lb).
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| Illustration 28 | g01627073 |
- Use a suitable punch in order to remove spring pins (48) .
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| Illustration 29 | g01627074 |
- Remove shaft (49) . Remove thrust discs (52) . Remove gear (51) . Remove bearings (50) . Repeat this procedure for the remaining gears.
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| Illustration 30 | g01627075 |
- Use Tooling (B) and a suitable lifting device in order to remove ring gear (53) . The weight of ring gear (53) is approximately 36 kg (80 lb).
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| Illustration 31 | g01627077 |
- Use two people in order to remove clutch piston (54) .
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| Illustration 32 | g01627082 |
- Remove seal rings (55) from clutch piston (54) .
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| Illustration 33 | g01627084 |
- Use Tooling (A) and a suitable lifting device in order to remove clutch housing (56) . The weight of clutch housing (56) is approximately 68 kg (150 lb).
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| Illustration 34 | g01627085 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Remove springs (57) . Remove pins (58) .
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| Illustration 35 | g01627086 |
- Remove discs (59) and plates (60) .
Note: Note the quantity and the order of discs (59) and plates (60) .
- Use two people in order to remove clutch piston (61) .
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| Illustration 36 | g01627185 |
- Remove seal rings (62) from clutch piston (61) .
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| Illustration 37 | g01627187 |
- Remove retaining ring (63) .
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| Illustration 38 | g01627188 |
- Use two people in order to remove hub (64) and sun gear (65) . The weight of hub (64) and sun gear (65) is approximately 27 kg (60 lb).
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| Illustration 39 | g01627192 |
- Remove retaining ring (66) in order to remove sun gear (65) from hub (64) .
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| Illustration 40 | g01627195 |
- Remove spacer (67) .
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| Illustration 41 | g01627196 |
- Use Tooling (B) and a suitable lifting device in order to remove planetary carrier (68) . The weight of planetary carrier (68) is approximately 125 kg (275 lb).
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| Illustration 42 | g01627198 |
- Use a suitable punch in order to remove spring pins (69) .
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| Illustration 43 | g01627199 |
- Remove shaft (70) . Remove thrust discs (73) . Remove gear (72) . Remove bearings (71) . Repeat this procedure for the remaining gears.
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| Illustration 44 | g01627201 |
- Remove retaining ring (74) . Remove sun gear (75) .
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| Illustration 45 | g01627205 |
- Remove bolts (76) and retainers (77) .
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| Illustration 46 | g01627209 |
- Use Tooling (B) and a suitable lifting device in order to remove clutch housing (78) and ring gear (79) . The weight of clutch housing (78) and ring gear (79) is approximately 113 kg (250 lb).
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| Illustration 47 | g01627278 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Use a suitable lifting device in order to remove ring gear (79) from clutch housing (78) . The weight of ring gear (79) is approximately 50 kg (110 lb).
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| Illustration 48 | g01627282 |
- Remove springs (80) . Remove pins (81) .
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| Illustration 49 | g01627285 |
- Remove discs (82) and plates (83) .
Note: Note the quantity and the order of discs (82) and plates (83) .
- Remove clutch piston (84) .
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| Illustration 50 | g01627288 |
- Remove seal rings (85) from clutch piston (84) .
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| Illustration 51 | g01627291 |
- Use two people in order to remove ring gear (86) .
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| Illustration 52 | g01627295 |
- Use Tooling (B) and a suitable lifting device in order to remove clutch housing (87) . The weight of clutch housing (87) is approximately 118 kg (260 lb).
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| Illustration 53 | g01627297 |
- Remove bolts (88) .
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| Illustration 54 | g01627298 |
- Use Tooling (B) and a suitable lifting device in order to remove planetary carrier (89) . The weight of planetary carrier (89) is approximately 68 kg (150 lb).
- Remove retaining ring (90) and O-ring seal (91) from bearing retainer (92) .
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| Illustration 55 | g01627307 |
- Use Tooling (D) in order to remove bearing (93) and bearing retainer (92) .
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| Illustration 56 | g01627309 |
- Use Tooling (D) and a suitable press in order to remove bearing retainer (92) from bearing (93) .
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| Illustration 57 | g01627311 |
- Use a suitable punch in order to remove spring pin (94) .
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| Illustration 58 | g01627314 |
- Remove shaft (95) , thrust washers (96) , gear (97) , and bearings (98) . Repeat this procedure for the remaining gears.
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| Illustration 59 | g01627317 |
- Remove discs (99) and plates (100) .
Note: Note the quantity and the order of discs (99) and plates (100) .
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| Illustration 60 | g01627320 |
- Use Tooling (B) and a suitable lifting device in order to remove hub (101) and sun gear (102) . The weight of hub (101) and sun gear (102) is approximately 36 kg (80 lb).
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| Illustration 61 | g01627324 |
- Remove seal rings (103) .
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| Illustration 62 | g01627325 |
- Remove retaining ring (104) in order to remove hub (101) from sun gear (102) .
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| Illustration 63 | g01627329 |
- Remove retaining ring (105) and retaining ring (106) .
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| Illustration 64 | g01627335 |
- Use Tooling (B) and a suitable lifting device in order to remove clutch housing (107) , clutch piston (108) , and balance piston (109) . The weight of clutch housing (107) , clutch piston (108) , and balance piston (109) is approximately 77 kg (170 lb).
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| Illustration 65 | g01627340 |
- Mark the alignment of clutch housing (107) , clutch piston (108) , and balance piston (109) for installation purposes.
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| Illustration 66 | g01627346 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Loosen bolts (110) slowly in order to release the spring pressure. After the spring pressure has been released, Remove bolts (110) .
- Use two people in order to remove clutch piston (108) and balance piston (109) from clutch housing (107) . The weight of clutch piston (108) and balance piston (109) is approximately 34 kg (75 lb).
- Remove retaining ring (111) .
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| Illustration 67 | g01627358 |
- Use Tooling (D) in order to remove bearing (112) .
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| Illustration 68 | g01627360 |
- Remove balance piston (109) from clutch piston (108) .
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| Illustration 69 | g01627363 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Remove seal rings (113) from balance piston (109) .
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| Illustration 70 | g01627364 |
- Remove springs (114) from clutch piston (108) .
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| Illustration 71 | g01627365 |
- Remove seal rings (115) from clutch piston (108) .
- Disconnect tube assembly (116) .
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| Illustration 72 | g01627367 |
- Attach Tooling (B) and a suitable lifting device onto manifold (117) and clutch (118) . The weight of manifold (117) and clutch (118) is approximately 136 kg (300 lb).
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| Illustration 73 | g01627371 |
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| Illustration 74 | g01627375 |
- Remove bolts (119) .
- Remove manifold (117) and clutch (118) .
- Loosen bolts (120) slowly in order to release the spring pressure. After the spring pressure has been released, remove bolts (120) .
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| Illustration 75 | g01627378 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Use two people in order to remove clutch piston (121) and balance piston (122) . The weight of clutch piston (121) and balance piston (122) is approximately 34 kg (75 lb).
- Remove balance piston (122) from clutch piston (121) .
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| Illustration 76 | g01627379 |
- Use Tooling (D) in order to remove bearing sleeve (123) from balance piston (122) .
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| Illustration 77 | g01627380 |
- Remove seal ring (124) from balance piston (122) .
- Remove springs (125) and seal ring (126) from clutch piston (121) .
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| Illustration 78 | g01627381 |
- Remove retaining ring (127) .
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| Illustration 79 | g01627383 |
- Use Tooling (B) and a suitable lifting device in order to remove clutch housing (128) . The weight of clutch housing (128) is approximately 50 kg (110 lb).
- Remove seal ring (129) .
- Remove seal ring (130) .
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| Illustration 80 | g01627385 |
- Use Tooling (D) in order to remove bearing (131) .
- Remove seal rings (132) .
Note: Note the location of seal rings (132) for installation purposes.
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| Illustration 81 | g01627387 |
- Remove seal rings (133) .
Note: Note the location of seal rings (133) for installation purposes.
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| Illustration 82 | g01627396 |
- Remove bolts (134) . Use a suitable lifting device in order to remove manifold (117) from ring carrier (135) . The weight of manifold (117) is approximately 73 kg (160 lb).
- Remove dowels (136) from ring carrier (135) .
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| Illustration 83 | g01627401 |
- Remove relief valve (137) and plugs (138) .
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| Illustration 84 | g01627407 |
- Remove cap (139) , spring (140) , washer (144) , valve (141) , body (142) , and O-ring seal (143) .
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| Illustration 85 | g01627411 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Remove balls (144) from manifold (117) .
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| Illustration 86 | g01627413 |
- Remove O-ring seal (145) from tube (146) .
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| Illustration 87 | g01627431 |
- Remove plug (147) and flange (148) in order to remove tube (146) .
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| Illustration 88 | g01627432 |
- Remove O-ring seal (149) and spring pin (150) from plug (147) .
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| Illustration 89 | g01627443 |
- Remove O-ring seal (151) from tube (146) .
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| Illustration 90 | g01627448 |
- Remove discs (152) and plates (153) .
Note: Note the quantity and the order of discs (152) and plates (153) for installation purposes.
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| Illustration 91 | g01627453 |
- Remove bolts (154) and retainers (155) .
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| Illustration 92 | g01627459 |
- Remove hub (156) .
- Use Tooling (E) and a suitable lifting device in order to remove planetary carrier (157) and shaft (158) . The weight of planetary carrier (157) and shaft (158) is approximately 113 kg (250 lb).
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| Illustration 93 | g01627470 |
- Position planetary carrier (157) and shaft (158) onto suitable blocking.
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| Illustration 94 | g01627478 |
- Use a suitable punch in order to remove pins (159) .
- Remove shaft (162) , thrust discs (163) , gear (160) , and bearings (161) . Repeat this procedure for the remaining gears.
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| Illustration 95 | g01627482 |
- Remove retaining ring (164) . Use two people in order to remove carrier housing (165) from shaft (158) .
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| Illustration 96 | g01627489 |
- Use Tooling (B) and a suitable lifting device in order to remove housing (166) . The weight of housing (166) is approximately 45 kg (100 lb).
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| Illustration 97 | g01627496 |
- Remove retaining ring (167) in order to remove sun gear (168) .
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| Illustration 98 | g01627501 |
- Use two people in order to remove plate (169) .
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| Illustration 99 | g01627502 |
- Remove discs (170) and plates (171) .
Note: Note the quantity and the order of discs (170) and plates (171) .
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| Illustration 100 | g01627504 |
- Remove hub (172) .
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| Illustration 101 | g01627509 |
- Loosen bolts (173) slowly in order to release the spring pressure. After the spring pressure has been released, remove bolts (173) .
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| Illustration 102 | g01627517 |
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Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force. |
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- Remove balance piston (174) .
- Remove seal ring (175) from balance piston (174) .
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| Illustration 103 | g01627519 |
- Remove springs (176) .
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| Illustration 104 | g01627521 |
- Remove clutch piston (177) .
- Remove seal ring (178) and seal ring (179) from clutch piston (177) .
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| Illustration 105 | g01627734 |
- Use Tooling (B) and a suitable lifting device in order to remove clutch housing (180) . The weight of clutch housing (180) is approximately 57 kg (125 lb).
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| Illustration 106 | g01627735 |
- Mark the alignment of cage (181) and clutch housing (180) for installation purposes.
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| Illustration 107 | g01627738 |
- Use a suitable drift in order to remove cage (181) from clutch housing (180) .
- Remove seal ring (182) , O-ring seals (183) , and bearing race (184) from cage (181) .
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| Illustration 108 | g01627739 |
- Remove seal ring (185) and bearing race (186) from clutch housing (180) .
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| Illustration 109 | g01627754 |
- Remove tube assembly (187) .
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| Illustration 110 | g01627757 |
- Remove O-ring seals (188) from tube assembly (187) .
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| Illustration 111 | g01627760 |
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