826K Landfill Compactor, 825K Soil Compactor and 824K Wheel Dozer Power Train Caterpillar

Disassembly Procedure

Start By:

1. Separate the transmission from the torque converter.

2. Remove the transmission hydraulic control valve.

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Illustration 1	g03654101

1. Attach Tooling (A) and a suitable lifting device to planetary assembly (1). The weight of planetary assembly (1) is approximately 565 kg (1246 lb).

2. Remove bolts (2) and the washers. Use Tooling (A) and the suitable lifting device in order to remove planetary assembly (1) from transmission housing (3).

3. Position planetary assembly (1) onto suitable cribbing. Do not remove Tooling (A) at this time.

   Note: Put alignment marks across the clutch housings for assembly purposes.

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   Illustration 2	g03654155

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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.

4. Attach Tooling (B) to clutch housing (4) in order to secure the clutch piston.

5. Remove bolts (5) and the washers. Use Tooling (A) and the suitable lifting device in order to remove clutch housing (4). The weight of clutch housing (4) is approximately 32 kg (70 lb).

6. Remove springs (6).
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   Illustration 3	g03654216

7. Remove clutch piston (7) from clutch housing (4).

8. Remove ring seals (8) from clutch piston (7).
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   Illustration 4	g03654228

9. Remove friction discs (9) and clutch plates (10).

10. Remove dowels (11).
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    Illustration 5	g03654233

11. Remove ring gear (12).
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    Illustration 6	g03654239

12. Remove retaining ring (14) and spacer (13).

13. Remove carrier assembly (15).
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    Illustration 7	g03654246

14. Use a suitable drift pin in order to bend locks (17) from bolts (16). Remove bolts (16), locks (17), slinger (18), and the gaskets from carrier assembly (15).
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    Illustration 8	g03654253

15. Use a suitable punch in order to drive spring pin (20) into shaft (19). Remove shaft (19) and spring pin (20) from carrier assembly (15). Remove spring pin (20) from shaft (19).
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    Illustration 9	g03654633

16. Remove thrust disc (21), planetary gear (23), and thrust disc (24) from carrier assembly (15).

17. Remove bearings (22) from planetary gear (23).

18. Repeat Steps 15 through 17 for the remaining planetary gears (23).
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    Illustration 10	g03654651

19. Remove dowels (25).

20. Remove retaining ring (26) and sun gear (27).
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    Illustration 11	g03654658

21. Attach Tooling (A) and a suitable lifting device to manifold assembly (29). The weight of manifold assembly (29) is approximately 73 kg (160 lb).

22. Remove bolts (28) and the washers. Use Tooling (A) and the suitable lifting device in order to remove manifold assembly (29).
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    Illustration 12	g03654672

23. Remove retaining ring (30) and bearing (31) from manifold assembly (29).

24. Remove O-ring seal (32).
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    Illustration 13	g03656519

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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.

25. Attach Tooling (A) and a suitable lifting device to clutch housing (33). The weight of clutch housing (33) is approximately 44 kg (97 lb).

26. Attach Tooling (C) (not shown) to clutch housing (33) in order to secure clutch piston (35) to clutch housing (33).

27. Remove bolts (34).

28. Use Tooling (A) and the suitable lifting device in order to remove clutch housing (33).
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    Illustration 14	g03656539

29. Remove clutch piston (35) from clutch housing (33). Remove ring seals (36) from clutch piston (35).
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    Illustration 15	g03656554

30. Attach Tooling (A) and a suitable lifting device to clutch housing (37). The weight of clutch housing (37) is approximately 45 kg (100 lb). Use Tooling (A) and the suitable lifting device in order to remove clutch housing (37).
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    Illustration 16	g03656650

31. Remove seal rings (39) from ring carrier (46).

32. Check the condition of ring carrier (38). If ring carrier (38) is worn or damaged, use new parts for replacement. DO NOT try to remove a damaged or worn ring carrier (38). Use a suitable hammer and chisel in order to break ring carrier (38). Remove the damaged ring carrier (38) and pin (40) from clutch housing (37).
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    Illustration 17	g03656660

33. Remove bolts (42) and the washers. Remove ring gear (41).
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    Illustration 18	g03656669

34. Remove friction discs (43) and clutch plates (44).
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    Illustration 19	g03656688

35. Remove dowels (45). Remove rotating housing (46).
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    Illustration 20	g03656692

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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.

36. Use Tooling (D) and a suitable press in order to apply force onto retainer plate (47) until retaining ring (48) can be removed. Release the force. Remove retainer plate (47) and remove disc springs (49).
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    Illustration 21	g03656694

37. Remove clutch piston (50) from clutch housing (37). Remove ring seals (51) from clutch piston (50).
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    Illustration 22	g03656700

38. Remove friction discs (52) and clutch plates (55).

39. Remove dowels (53) and springs (54).
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    Illustration 23	g03657017

40. Remove retaining ring (56).

41. Attach Tooling (A) and a suitable lifting device to carrier assembly (57). The weight of carrier assembly (57) is approximately 26 kg (57 lb). Use Tooling (A) and the suitable lifting device in order to remove carrier assembly (57).
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    Illustration 24	g03657019

42. Remove retaining ring (58). Remove hub assembly (59) from carrier assembly (57).
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    Illustration 25	g03657024

43. Use a suitable screw driver in order to compress retaining ring (60) (not shown). Remove ring gear (61) from carrier assembly (57).
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    Illustration 26	g03657027

44. Remove retaining ring (62). Remove bearing (63) from carrier assembly (57).
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    Illustration 27	g03657029

45. Use a suitable punch in order to drive spring pin (65) into shaft (64). Remove shaft (64) and spring pin (65) from carrier assembly (57). Remove spring pin (65) from shaft (64).
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    Illustration 28	g03657035

46. Remove thrust disc (66), planetary gear (67), and thrust disc (69) from carrier assembly (57).

47. Remove bearing (68) from planetary gear (67).

48. Repeat Steps 45 through 47 for the remaining planetary gears (67).
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    Illustration 29	g03657056

49. remove sun gear (70).
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    Illustration 30	g03657057

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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.

50. Attach Tooling (A) and a suitable lifting device to clutch housing (71). The weight of clutch housing (71) is approximately 44 kg (97 lb). Attach Tooling (B) to clutch housing (71) in order to secure the clutch piston to clutch housing (71).

51. Remove bolts (72).

52. Use Tooling (A) and the suitable lifting device in order to remove clutch housing (71).

53. Remove springs (73) and dowels (74).
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    Illustration 31	g03657059

54. Remove clutch piston (75) from clutch housing (71). Remove ring seals (76) from clutch piston (75).
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    Illustration 32	g03657063

55. Remove friction discs (77) and clutch plates (78).
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    Illustration 33	g03657066

56. Remove ring gear (79) and plate (80).
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    Illustration 34	g03657068

57. Remove friction discs (81) and clutch plates (82).
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    Illustration 35	g03657070

58. Remove clutch piston (83).
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    Illustration 36	g03657074

59. Remove ring seals (84) from clutch piston (83).
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    Illustration 37	g03657082

60. Remove retaining ring (85).
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    Illustration 38	g03657086

61. Remove speed adapter (86).
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    Illustration 39	g03657087

62. Remove retaining ring (87).
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    Illustration 40	g03657094

63. Remove retaining ring (88).
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    Illustration 41	g03657090

64. Position shaft assembly (87) onto suitable cribbing. Use a suitable soft hammer in order to strike input shaft (89) until input shaft (89) can be removed from shaft assembly (87).
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    Illustration 42	g03657125

65. Remove retaining ring (90) and remove bearing (91) from input shaft (89).

66. Remove O-ring seals (92) and (93).
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    Illustration 43	g03657128

67. Use Tooling (F) and a suitable press in order to remove seal carrier (95) from output shaft (94).
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    Illustration 44	g03657133

68. Use Tooling (G) in order to remove bearing (96) (not shown) from output shaft (94).
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    Illustration 45	g03657136

69. Remove gear (97).
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    Illustration 46	g03657139

70. Use two people in order to remove carrier assembly (98) and ring gear (99) as one. The combined weight of carrier assembly (98) and ring gear (99) is approximately 28 kg (61 lb).
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    Illustration 47	g03657142

71. Remove retaining ring (100) and bearing (101).
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    Illustration 48	g03657145

72. Remove seal ring (102). Use a suitable screw driver in order to compress retaining ring (103) (not shown). Remove ring gear (99).
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    Illustration 49	g03657146

73. Use a suitable punch in order to drive spring pin (105) into shaft (104). Remove shaft (104) and spring pin (105) from carrier assembly (98). Remove spring pin (105) from shaft (104).
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    Illustration 50	g03657147

74. Remove thrust disc (106), planetary gear (107), thrust disc (109), thrust disc (110), planetary gear (112), and thrust disc (113) from carrier assembly (98).

75. Remove bearing (108) from planetary gear (107). Remove bearing (111) from planetary gear (112).

76. Repeat Steps 73 through 75 for the remaining planetary gears.
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    Illustration 51	g03657903

77. Remove gear (114) and spacer (115) (not shown).

78. Use a suitable screw driver in order to compress retaining ring (116) (not shown). Remove ring gear (117).
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    Illustration 52	g03657914

79. Remove retaining ring (118). Remove bearing (119) and clutch housing (120) as one.
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    Illustration 53	g03657910

80. Remove retaining ring (121). Use Tooling (H) in order to remove bearing (119) from clutch housing (120).
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    Illustration 54	g03657920

81. Remove metal seal rings (122), (126), and (128) from carrier assembly (125).

82. Remove lock ring (127).

83. Remove retaining ring (123). Use Tooling (H) in order to remove bearing (124).
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    Illustration 55	g03657923

84. Use a suitable punch in order to drive spring pin (130) into shaft (129). Remove shaft (129) and spring pin (130) from carrier assembly (125). Remove spring pin (130) from shaft (129).
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    Illustration 56	g03657933

85. Remove thrust disc (131), planetary gear (133), and thrust disc (134) from carrier assembly (125).

86. Remove bearing (132) from planetary gear (133).

87. Repeat Steps 84 through 86 for the remaining planetary gears (133).