785G Off-Highway Truck Power Train Caterpillar

Removal Procedure

Start By:

1. Remove the axle housing.

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When you are using hydraulic cylinders and puller studs, always ensure that the rated capacity of the puller stud meets or exceeds the rated capacity of the hydraulic cylinder. If the puller stud does not meet or exceed the rated capacity of the hydraulic cylinder, a sudden failure of the puller stud could occur. The sudden failure of the puller stud could result in personal injury or death.

Note: Put identification marks on all hose assemblies, on all tube assemblies and on all wire harnesses for installation purposes. Plug all hose assemblies and all tube assemblies. Marking helps to prevent fluid loss and prevent contaminants from entering the system.

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Illustration 1	g06284267

1. Remove two bolts (1), hardware (2), and position hoses (3) out of the way.
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   Illustration 2	g06284448

2. Remove three bolts (4) and transmission filter assembly (5).
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   Illustration 3	g06284713

3. Attach a suitable lifting device (6) to raise shaft (8) and remove cribbing (9).

4. Install cribbing (7) to support shaft (8).
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   Illustration 4	g06284727

5. Remove all mounting hardware (10) and disconnect harness (11).
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   Illustration 5	g06284792

6. Remove all mounting hardware (12).

7. Remove bolts (14).

8. Disconnect harness (11) at positions (13) and (15) and position out of the way.
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   Illustration 6	g06284802

9. Remove all mounting hardware (16) and harness (11).
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   Illustration 7	g06284847

10. Remove mounting hardware (17) and three hoses (18).
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    Illustration 8	g06285186

11. Install Tooling (B) and a suitable lifting device. The accumulator assembly (20) weighs approximately 135 kg (297.6 lb).

12. Remove six bolts (19) and accumulator assembly (20).
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    Illustration 9	g06285806

13. Use a suitable lifting device to hold support (21). The weight of support (21) is approximately 1400 kg (3086.5 lb). Ensure that the straps in position (Z) are sufficiently far from the frame at position (X) to remove support (21). Support (21) must be moved toward position (X) before lowering.
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    Illustration 10	g06285548
    View from underneath.

14. Remove six bolts (22) and plate (23) and shims.
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    Illustration 11	g06285553

15. Remove eight bolts (24) and two caps (25).
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    Illustration 12	g06285554

16. Remove ring (28), pin (26), and thrust washer (27). Thrust washer (27) not shown.
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    Illustration 13	g06285870
    Repeat on opposite side.

17. Remove four bolts (29) and plate (30).
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    Illustration 14	g06285954

18. Move support (21) to suitable cribbing.

19. Remove 12 bolts (31) and two plates (32).
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    Illustration 15	g06286254
    Typical example of cylinder group.

20. Use Tooling (A) to remove bearing (33).

Installation Procedure

1. Tighten 12 bolts (31) to a torque of 270 ± 25 N·m (199 ± 18 lb ft).

2. Tighten eight bolts (24) to a torque of 500 ± 50 N·m (369 ± 37 lb ft)
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   Illustration 16	g06286308

3. Assemble plate (23) to pin (26) using three bolts (22) as shown. Tighten bolts (22) to a torque of 200 ± 25 N·m (148 ± 18 lb ft). Measure distance (Y) between plate (23) and pin (26). Add shim pack equal to measured distance plus 0.25 mm (0.01 inch). Tighten six bolts (22) to a final torque of 750 ± 90 N·m (553 ± 66 lb ft).

4. Tighten all M10 mounting hardware to a torque of 35 ± 5 N·m (26 ± 4 lb ft).