D6 TRACTOR POWER TRAIN Caterpillar

Transmission (Direct Drive And Special Application)

Usage:

Remove Transmission (Direct Drive & Special Application)

start by:

a) remove seat and seat frame

b) remove universal joint (DIRECT DRIVE & SPECIAL APPLICATION)

c) remove brake pedal assembly

1. Remove the oil from the transmission and the steering clutch case.

2. Disconnect the two steering clutch control rods (1).

3. Disconnect rod (2) for the transmission interlock mechanism.

4. Remove the oil line from the flywheel clutch to the steering clutch case.

5. Remove the oil line from the flywheel clutch to the oil cooler.

6. Disconnect the oil line from the transmission to the oil filter.

7. Remove the oil line from the flywheel clutch to the steering clutch hydraulic control valve.

8. Remove two of the bolts that hold the top cover to the transmission. Install two 3/8"-16 NC forged eyebolts (4) in the transmission as shown.

9. Fasten a hoist to the transmission. Weight of the transmission is 500 lb. (227 kg). Remove the nuts (3) that hold the transmission to the steering clutch case.

10. Install two 1/2"-13 NC forcing screws in the transmission case. Make a separation of the transmission from the steering clutch case. Remove the transmission (5).

Install Transmission (Direct Drive & Special Application)

1. Fasten a hoist to the transmission. Put the transmission in position in the steering clutch case.

NOTE: Make sure the pinion shaft in the transmission is in correct alignment with the bevel gear. See INSTALL BEVEL GEAR AND SHAFT (DIRECT DRIVE & SPECIAL APPLICATION).

2. Install the nuts (1) that hold the transmission to the steering clutch case. Remove the hoist and eyebolts. Install the two bolts in the top cover of the transmission.

3. Install the oil line from the flywheel clutch to the steering clutch hydraulic control valve.

4. Install the oil line from the transmission to the oil filter.

5. Install the oil line from the flywheel clutch to the oil cooler.

6. Install the oil line from the flywheel clutch to the steering clutch case.

7. Install the two steering clutch control rods (2).

8. Connect rod (3) from the transmission interlock mechanism.

9. Fill the transmission and steering clutch case with oil to the correct level. See LUBRICATION AND MAINTENANCE GUIDE.

end by:

a) install universal joint (DIRECT DRIVE & SPECIAL APPLICATION)

b) install brake pedal assembly

c) install seat and seat frame

Disassemble Transmission (Direct Drive & Special Application)

start by:

a) remove transmission (DIRECT DRIVE & SPECIAL APPLICATION)

1. Remove cover (1) from the shift lever.

2. Remove bolts (4) and washers that hold the shift lever to the cover.

3. Remove shift lever (3), springs, and lever (2) from the cover.

4. Remove washer (5), gaskets (6) and plate (7) from lever (3).

5. Remove cotter pin (11), cover (9), packing (8) and plate (10) from lever (3).

6. Remove the bolts (12) and cover (13) for the interlock mechanism.

7. Remove the plate for the interlock mechanism.

8. Remove the plate from shaft (16). Remove shaft (16) and lever (14) from the cover. Remove the seal (15) from the cover.

9. Remove the springs (17) and plungers (18) from the interlock mechanism of the gear shift cover.

10. Install two 3/8"-16 NC forged eyebolts in the gear shift cover.

11. Fasten a hoist to the gear shift cover. Weight of the gear shift cover is 84 lb. (38 kg). Remove the gear shift cover and shift forks from the transmission.

12. Disassemble the gearshift cover and forks as follows:

a) Remove the wire that keeps bolt (19) in position.

b) Remove bolt (19) from fork (21).

c) Remove cover (20).

d) Pull shaft (22) out of the cover and remove fork (21). Remove the wire from bolt (23). Remove the bolt.

e) Pull shaft (25) out of the cover and remove fork (24).

f) Remove the wire from the bolt that holds fork (26) in position on shaft (28). Remove shaft (28) and fork (26) from the cover. Remove the wire from bolt (30). Remove the bolt. Remove shaft (29) and fork (27) from the cover.

g) Remove the bolts and locks that hold plate (33) in position. Remove the plate. Loosen the bolt in lever (32). Remove the lever and shaft (31) from the cover. Remove the two keys from shaft (31). Remove two bearings (34) from the cover.

h) Remove the cotter pin that holds lever (35) in position on the shaft. Remove lever (35). Remove the dowel that holds the shaft in the cover with a hammer and punch. Remove the shaft from the cover.

i) Remove the two locks and bolts that hold gate (36) in position. Remove gate (36).

j) Remove the seal for the gearshift lever from the cover.

13. Remove the two bolts, locks, washers and seal that hold the flange on the shaft.

14. Remove flange (37) with tooling (A).

15. Remove bolts (38) that hold cover (39) to the transmission case. Remove cover (39).

16. Install the cover with three bolts as shown.

NOTE: Make sure the three bolts are installed evenly around the cover.

17. Install tooling (B) as shown.

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NOTICE

To prevent damage to the cover, put the puller in position so the legs of the puller are pulling at the point where the bolts are installed.

18. Use tooling (B) to push the forward-reverse shaft from the case.

19. Remove tooling (B) and the cover.

20. Remove the seal from the cover with tooling (C).

21. Remove bearing cup (44), bearing cone (43), spacer (42) and bearing cone (41) from cage (40).

NOTE: Put identification on the bearing cups and bearing cones to prevent mixing during installation in the transmission case.

22. Check the seal on the cage for damage. If the seal is damaged, use new parts for replacement.

23. Pull shaft (46) out of the transmission case and remove gear (45).

24. Remove shaft (46) from the transmission case.

25. Remove ring (47) that holds bearing (48) on the shaft.

26. Remove bearing (48) from the shaft with a press.

27. Install three 1/2"-13 NC forcing screws in the cage for the upper shaft. Make a separation of the cage from the transmission case.

28. Remove bearing cup (49) from the cage with a hammer and punch.

29. Remove cover (50) from the transmission case.

30. Check seal (53) for damage. If the seal is damaged, use new parts for replacement.

31. Remove two bolts (54), lock and retainer (51) from the shaft.

32. Install three 1/2"-13 NC forcing screws in cage (52) and make a separation of the cage from the transmission case.

33. Remove shims (55).

NOTE: Make a mark on the shims so they can be installed in the same position during assembly.

34. Check seal (56) for damage. If the seal is damaged, use new parts for replacement.

35. Remove cage (52) from the shaft with tooling (B).

36. Remove bearing and bearing race (57) from the cage.

37. Remove spacer (58) from the shaft.

38. Install bolts (59) of tooling (D) in the reverse idler gear. Use tooling (D) to loosen the bearing in the reverse idler gear.

39. Remove bearing cone (60) from the shaft.

40. Remove gear (61) from the shaft.

NOTE: The gear in the Special Application Transmission is removed the same way that gear (61) is removed. The gear looks different because the transmission in the Special Application machine is a 6 speed transmission.

41. Remove spacer (64) from the shaft.

42. Move gear (62) forward. Remove bearing cone (63) from the shaft with a soft hammer.

43. Remove bearing cups (65) and (66) from the reverse idler gear.

44. Pull shaft (68) out of transmission case. Remove gears (67) from the shaft as the shaft is being removed from the transmission case.

45. Remove the ring that holds bearing (69) on shaft (68). Remove the bearing from the shaft with tooling (E).

46. Remove two bolts (70), lock and retainer (71).

47. Remove bolts (72) and cover (73) from the transmission case.

48. Check seal (74) on cage (76) for damage. If the seal is damaged, use new parts for replacement.

49. Remove two bolts (75), lock, washer (77) and plate.

50. Install three 1/2"-13 NC forcing screws in cage (76) and make a separation of the cage from the transmission case.

51. Remove cage (76) from the transmission case with tooling (F). Tooling (F) will push the shaft out of the transmission case. Remove tooling (F). Remove the spacer and bearing from the end of the shaft.

52. Remove the plug and dowel that holds the bearing race in cage (76). Remove the bearing race from the cage.

53. Pull shaft (78) out of the transmission case. Remove the six gears and spacer as the shaft is being removed from the transmission case.

54. Remove bearing (79) and spacer (80) from the shaft with tooling (G).

55. Remove bolts (81) and lock that holds the tube in the transmission case.

56. Remove the tube from the transmission case.

57. Remove the plugs that hold the dowels in the transmission case with tool (H). Remove the dowels that hold bearing races (82) in position with a 6-40 screw. Remove the dowels that hold bearing races (83) in position with a 1/4"-20 NC bolt.

58. Remove bearing races (82) and (83) from the transmission case.

Assemble Transmission (Direct Drive & Special Application)

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NOTICE

Before assembling the transmission, clean the transmission case and make sure the oil passages are clean and free of dirt and foreign material.

1. Install tube (1) in the transmission case. Install the lock and bolts that hold the tube in position.

2. Lower the temperature of bearing races (2), (3) and (4). Install the bearing races in the transmission case. Make sure the holes in the bearing races are in alignment with the holes in the transmission case.

3. Install dowels (5) in the transmission case. Install new plugs that hold the dowels in position.

4. Put spacer (7) on shaft (8). Heat bearing (6) in oil to a maximum temperature of 275°F (135°C). Install bearing (6) on shaft (8) as shown.

5. Install three 3/8"-16 NC forged eyebolts in the front of the transmission case. Fasten a hoist to the transmission case.

6. Lift the transmission case until shaft (8) can be installed under the transmission case. Lower the transmission case half way on to the shaft.

7. Put gear (9), spacer (10), gear (11) and gear (12) on the shaft. Lower the transmission case more on to the shaft. Install gears (13), (14) and (15) on the shaft. Lower the transmission case all of the way down.

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NOTICE

Make sure bearing (6) is in alignment with the bearing race in the transmission case.

8. Remove the hoist from the transmission case and install spacer (16) on the shaft.

9. Lower the temperature of bearing race (10) and install the bearing race in cage (18). Make sure the hole in the bearing race is in alignment with the hole in the cage.

10. Install dowel (17) that holds the bearing race in the cage.

11. Put the cage in position in the transmission case. Install three 3/8"-16 NC bolts 1 1/2" long in the cage. Tighten the bolts until the cage makes contact with the transmission case. Remove the three bolts.

12. Put bearing (20) in position on the end of the shaft. Install the bearing on the shaft using retainer (21) and two 3/8"-24 NF bolts 2 in. long. After the bearing is installed, remove the two bolts.

13. Install retainer (21), lock and bolts that hold the retainer to the shaft.

14. Install the plate in the cage and over the shaft.

15. Install a new seal (25) in the cage. Put clean SAE 30 oil on the seal.

16. Put cover (23) on the cage with groove (22) in alignment with groove (24).

17. Install retainer (28), lock (27) and bolts (26) on the end of shaft (8).

18. Heat bearing (29) in oil to a maximum temperature of 275°F (135°C). Install the bearing on shaft (31). Install ring (30) on the shaft.

19. Clean the oil hole and oil passages on shaft (31).

20. Lower the temperature of bearing cups (32) and (33). Install the bearing cups in the reverse idler gear.

21. Install two 3/8"-16 NC forged eyebolts in the front of the transmission case. Fasten a hoist to the transmission case.

22. Lift the transmission case and put shaft (31) in position under the bore in the transmission case. Lower the transmission case half way on to the shaft.

23. Lower the temperature of inner bearing cup for cage (34) and install it into the cage with tooling (A).

24. Put gears (35), (36) and (37) on the shaft.

25. Heat bearing cone (38) in oil to a maximum temperature of 275°F (135°C). Install the bearing on the shaft as shown.

26. Put spacer (40) and the reverse idler gear (39) on the shaft.

27. Heat bearing cone (41) in oil to a maximum temperature of 275°F (135°C). Install the bearing on the shaft as shown.

28. Put spacer (42) on the shaft as shown.

29. Lower the transmission case all of the way down on the shaft.

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NOTICE

Make sure that bearing (29) is in alignment with the bearing race in the transmission case.

30. Put shims (43) in the correct position on the transmission case.

31. Install a new seal (44) on cage (34). Put clean SAE 30 oil on the seal.

32. Make sure the oil hole in the cage is clean and free of dirt.

33. Put cage (34) in the transmission case (45) with oil hole in alignment with the oil passage in the transmission case.

34. Heat bearing cone (47) in oil to a maximum temperature of 275°F (135°C). Install the bearing on the shaft.

35. Install spacer (48). Heat bearing cone (49) in oil to a maximum temperature of 275°F (135°C). Install the bearing on the shaft. Use retainer (50) and two 3/8" - 24 NF bolts 2 in. long to install the bearing cone on the shaft. Remove the two bolts. Lower the temperature of bearing cup (46) and install the bearing cup in the cage.

36. Install a new seal (51) on the cage. Put clean SAE 30 oil on the seal.

37. Clean the oil passage in retainer (50). Install a new seal (53). Put clean SAE 30 oil on the seal.

38. Install retainer (50), lock and bolts (52).

39. Put cover (54) in position on the cage so the groove in the cover is in alignment with the groove in the cage. Install bolts (55).

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NOTICE

Do not damage seal (53) when installing the cover.

40. Fasten a hoist to the transmission. Put the transmission in a horizontal position.

41. Heat bearing (57) in oil to a maximum temperature of 275°F (135°C). Install the bearing on the shaft. Install ring (56) that holds the bearing in position.

42. Put shaft (59) half way into the transmission case. Install forward-reverse gear (58). Push the shaft all of the way into the transmission case.

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NOTICE

Make sure that bearing (57) is in alignment with the bearing race in the transmission case.

43. Make sure the oil hole in the cage for the upper shaft is clean and free of dirt.

44. Lower the temperature of the bearing cup and install it in cage (60).

45. Put cage (60) in position on the transmission case. Make sure the oil hole in the cage is in alignment with the oil hole in the transmission case. Put cover (61) in position over the cage and install bolts (62). Tighten the bolts until the cage is in all of the way.

46. Remove bolts (62) and cover (61) from cage (60).

47. Heat bearing cone (65) in oil to a maximum temperature of 275°F (135°C). Install the bearing cone on the shaft. Install spacer (63).

48. Heat bearing cone (66) in oil to a maximum temperature of 275°F (135°C). Install the bearing on the shaft.

49. Lower the temperature of bearing cup (67). Install the bearing cup in the cage.

50. Install seal (64) in cover (61) with tooling (B). Install the seal with the lip of the seal toward the inside.

51. Install a new seal on the cage. Put clean SAE 30 oil on the seal.

52. Install cover (69) and bolts (70).

53. Put flange (71) in position on the upper shaft. Install the flange on the upper shaft (59) with retainer (73) and two 3/8" - 24 NF bolts 2 in. long. After the flange is installed, remove the two bolts.

54. Put a new seal between the retainer and the upper shaft. Put clean SAE 30 oil on the seal.

55. Install retainer (73), lock and bolts (72).

56. Assemble the gear shift cover and forks as follows:

a) Install the seal in the cover with tooling (D). Install the seal with the lip toward the outside of the cover.

b) Install the two bearings in the cover with tooling (E).

c) Put gate (76) in position in the cover as shown. Install the two locks and bolts that hold it.

d) Put shaft (74) in position in the cover. Install the dowel that holds it.

e) Install the bearing in lever (75) with tooling (F). Put the lever in position on the shaft. Install the cotter pin that holds it.

f) Put lever (77) in position in the cover. Install the two keys in the shaft. Install shaft (78) in the cover and through the lever.

g) Put plate (79) into position in the cover. Install the locks and bolts that hold it. Put fork (80) into position in the cover. Install the shaft through the cover and into the fork (80). Install the bolt and wire that holds the fork to the shaft.

h) Put fork (83) into position in the cover. Install shaft (84) in the cover and through the fork. Install the bolt and wire that holds the fork to the shaft.

i) Put fork (81) into position in the cover. Install the shaft (86) through the cover and into fork (81). Install the bolt and wire that holds the fork to the shaft.

j) Put fork (82) into position in the cover. Install the shaft (85) through the cover and into the fork. Install the bolt and wire that holds the fork to the shaft.

57. Fasten a hoist to the cover for the shifter forks. Put the cover in the correct position on the transmission. Make sure the forks are in the correct grooves for their respective gears.

58. After the forks are in the correct position on the gears, lower the cover on to the transmission. Install the bolts and washers that hold the cover to the transmission.

59. Install cover (87), spring (93), cover (88), packing, cover (94), gasket (89), plate (90) and cotter pin (95) on the shift lever.

60. Put gaskets (91), plate (96) and ring (92) in position on the shift lever.

61. Install the seal in the interlock mechanism housing with tooling (C). Install the seal with the lip toward the inside of the housing.

62. Install the shaft and lever in the interlock mechanism housing.

63. Put plate (97) in the housing as shown.

64. Install the springs and plungers in the interlock mechanism. Make sure the plungers are installed with the bevel on the plungers toward the rear of the transmission.