24 Motor Grader Power Train Caterpillar

Transfer Gears - Disassemble - Output

Usage:

24 E9Z

Disassembly Procedure

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Table 1
Required Tools
Tooling	Part Number	Part Description	Qty
A	1P-5546	Crossarm	1
	8T-4123	Washers	6
	7X-2564	Bolt	2
	8T-4141	Bolt	1
B	1P-0532	Handle	1
B	1P-0525	Drive Plate	1
C	439-3939	Link Bracket As	3
D	439-3940	Link Bracket As	2
E	422-5473	Lifting Eye Assembly	3
F	1U-6342	Threaded Rod M10 x 1.5 x 120mm	3
	2Y-5829	Nuts	3
	6V-5839	Washers	3
	1P-0532	Handle	1
G	1P-0507	Drive Plate	1
H	1P-0524	Drive Plate	1
	1P-0524	Drive Plate	1
	1P-0532	Handle	1
J	1U-6400	Three Jaw Puller	1
J	1P-0496	Drive Plate	1
K	-	Loctite 5127	-
L	1U-9889	Crossblock	1
	3H-0468	Puller Plates	2
	3H-0469	Legs	2
	3H-0469	Legs	2
	1P-0527	Drive Plate	1
	1P-0527	Drive Plate	1
	360-6970	Cylinder	1
	6V-8237	Washers	2
M	8T-3282	Hard Washers	2
	3H-0465	Push-Puller Plates	2
	1P-5546	Crossarm	1
	1P-0496	Drive Plate	1
	4C-9431	Forcing Bolt	1
	5F-7369	Puller Legs	2
	8B-7551	Bearing Puller Gp	1
	-	Nuts M20 x 1.5 JIS	2
	-	Nuts M20 x 1.5 JIS	2

Start By:

Separate the transmission and transfer gears (Output).

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Illustration 1	g06269711

Remove bolt (1), retainer (2), and the seal ring.
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Illustration 2 g06269715
Use Tooling (A) to remove yoke (3).
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Illustration 3 g06272312

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Illustration 4 g06272314
Remove bolts (4).
Use two bolts (4) at location (U) and tighten to remove bearing cage (5). Remove the seal ring from bearing cage (5).
Remove tube (6).
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Illustration 5 g06278132
Remove lip seal (7).
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Illustration 6 g06272316
Remove retaining ring (8).
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Illustration 7 g06272317
Use Tooling (B) to remove bearing (9).
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Illustration 8 g06274261
Install Tooling (C) and a suitable lifting device to transfer gear assembly (10). The weight of transfer gear assembly (10) is approximately 925 kg (2040 lb).
Install Tooling (D) and a suitable lifting device to the transfer gear assembly (10) at location (Z). The weight of transfer gear assembly (10) is approximately 925 kg (2040 lb).
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Illustration 9 g06276306
Use Tooling (D) to raise transfer gear assembly vertically.
Remove Tooling (C) and rotate transfer gear assembly (10).
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Illustration 10 g06274269
Install Tooling (C) and a suitable lifting device to transfer gear assembly (10) at location (Y). The weight of transfer gear assembly (10) is approximately 925 kg (2040 lb).
Repeat Step 13 for the opposite side of the gear case.
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Illustration 11 g06272322
Rotate transfer gear assembly (10) and position on suitable cribbing.
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Illustration 12 g06272323
Remove bolts (11), cover (12), and the seal ring.
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Illustration 13 g06272324

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Illustration 14 g06272328
Remove bolts (13).
Install two bolts (13) at location (X) and tighten to release the cover assembly (14) from the gear case.
Attach tooling (E) and a suitable lifting device to the cover assembly (14). The weight of cover assembly (14) is approximately 209 kg (460 lb).
Remove cover assembly (14) and the seal ring.
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Illustration 15 g06272384
Remove bolt (15) and retainer (16).
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Illustration 16 g06272823
Position shaft and gear assembly (18) allowing access to bolts (17).
Remove bolts (17).
Note: Reposition shaft and gear assembly (18) for access to remaining bolts (17).
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Illustration 17 g06274443
Attach Tooling (E) and a suitable lifting device to cover assembly (14). The weight of cover assembly (14) is approximately 209 kg (460 lb).
Attach Tooling (F) and cover (12) to cover assembly (14).
Attach a suitable lifting device to shaft and gear assembly (18). The weight of shaft and gear assembly is approximately 118 kg (260 lb).
Use Tooling (F) to remove shaft and gear assembly (18).
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Illustration 18 g06273764
Remove bearing cup (19).
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Illustration 19 g06274212

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Illustration 20 g06274068
Place appropriate indication marks on the cups and the cones on bearing (20).
Note: Bearing (20) is a match bearing set. The cup and cone combination must stay the same before and after assembly.
Attach a suitable lifting device to shaft and gear assembly (18). The weight of shaft and gear assembly is approximately 118 kg (260 lb). Position shaft and gear assembly into a suitable press.
Position a suitable cart and cribbing under the press to support shaft (24). The weight of shaft (24) is approximately 56 kg (124 lb).
Use Tooling (G) and a suitable press to remove shaft (24).
Remove bearing (20).
Remove flange (21).
Remove collar (22).
Attach a suitable lifting device to gear (23). The weight of gear (23) is approximately 49 kg (108 lb).
Remove gear (23).
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Illustration 21 g06272827

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Illustration 22 g06272832
Remove bolts (25).
Install two bolts (25) at location (W) and tighten to remove cover (28).
Remove bearing cage (28), the shim, and the seal ring.
Remove bolts (26), cover (27), and the seal ring.
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Illustration 23 g06272842
Remove bearing cup (29) from bearing cage (28).
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Illustration 24 g06274214

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Illustration 25 g06270756
Attach Tooling (E) and a suitable lifting device to the transfer gear cover (31). The weight of transfer gear cover (31) is approximately 82 kg (180 lb).
Remove bolts (30).
Install two bolts (30) at location (V). Tighten two bolts (30) evenly in 1/2 turn increments to remove cover (31) as evenly as possible. This procedure will prevent damage to the race due to uneven positioning of the idler bearing.
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Illustration 26 g06274216
Use tooling (H) to remove the outer bearing.
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Illustration 27 g06274134
Remove bolts (32) and mount (33).
Remove bolts (34), cover (35) and the seal ring.
Repeat Steps 47 through 48 for the opposite side of the gear case.
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Illustration 28 g06279827
Use a suitable lifting device to remove gear assembly (36). The weight of gear assembly (36) is approximately 52 kg (115 lb).
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Illustration 29 g06274242
Use a suitable lifting device to position gear assembly (36) in a suitable vise. The weight of gear assembly (36) is approximately 52 kg (115 lb).
Attach Tooling (J) to bearing race (37).
Raise the temperature of bearing race (37). Use Tooling (J) to remove bearing race (37).
Repeat Steps 51 through 53 for the opposite side of gear assembly (36).
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Illustration 30 g06279746
Remove sensors (39).
Use a suitable lifting device to remove gear assembly (38). The weight of gear assembly (38) is approximately 72 kg (158 lb).
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Illustration 31 g06274247
Use Tooling (L) to remove bearing cone (40).
Repeat Step 57 for the opposite side of gear assembly (38).
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Illustration 32 g06274148
Remove bearing (41) and bearing cone (42).
Remove nuts (43), cover (44), and the seal ring.
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Illustration 33 g06274151
Position a suitable piece of cribbing under gear (45).
Remove inner retaining ring (46), outer retaining ring (47), and gear (45).
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Illustration 34 g06274152
Remove bearing (48).
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Illustration 35 g06274154
Remove bolt (50) and tube (49).
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Illustration 36 g06274611
Attach Tooling (M) to shaft (24).
Raise the temperature of bearing race (51). Use Tooling (M) to remove bearing race (51).