525B and 535B Wheel Skidders Power Train Caterpillar

Disassembly Procedure

Start By:

1. Separate the torque converter from the transmission. Refer to Disassembly and Assembly, "Torque Converter from Transmission - Separate" for the machine that is being serviced.

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

Note: Put identification marks on all sections of the transmission for assembly purposes.

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Illustration 1	g00594845

1. Install Tooling (A) to shaft (2). Attach a hoist and a suitable lifting sling to Tooling (A).

   Note: Hold input shaft (1) away from shaft (2) for clearance.

2. Use the hoist to lift shaft (2) straight up out of transmission case (3). The weight of the shaft is 45 kg (100 lb).
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   Illustration 2	g00594849

3. Install Tooling (A) to shaft (4). Attach a hoist and a suitable lifting sling to Tooling (A).

   Note: Hold input shaft (1) away from shaft (4) for clearance.

4. Use the hoist to lift shaft (4) straight up out of transmission case (3). The weight of the shaft is 52 kg (115 lb).
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   Illustration 3	g00594850

5. Install Tooling (A) to shaft (5). Attach a hoist and a suitable lifting sling to Tooling (A).

6. Use the hoist to lift shaft (5) straight up out of transmission case (3). The weight of the shaft is 79 kg (175 lb).
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   Illustration 4	g00594854

7. Remove thrust disc (6) from transmission case (3).
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   Illustration 5	g00594857

8. Install Tooling (A) to input shaft (1). Attach a hoist and a suitable lifting sling to Tooling (A).

9. Use the hoist to carefully remove input shaft (1) from transmission case (3). The weight of the input shaft is 20 kg (45 lb).
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   Illustration 6	g00594861

10. Rotate the transmission case, as shown. Loosen jam nut (8) and disconnect actuator rod (9) from parking brake actuator (7).

11. Remove eight bolts (9), the washers, and brake drum (10).
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    Illustration 7	g00594863

12. Remove bolt (11), yoke retainer (12), O-ring seal (13), and yoke (14) from transmission case (3).
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    Illustration 8	g00594865

13. Remove four bolts (15), the washers, and parking brake (16) from transmission case (3).
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    Illustration 9	g00594867

14. Rotate the transmission case, as shown. Use Tooling (B) to remove roller bearing cone (18) from output shaft (17).
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    Illustration 10	g00594869

15. Turn the transmission case to the opposite side. Remove ten bolts (19) and the washers from bearing cage (20).
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    Illustration 11	g00594886

16. Install Tooling (C) to bearing cage (20). Attach a hoist and suitable lifting slings to Tooling (C).

17. Use two bolts (19) as forcing screws to loosen bearing cage (20) from transmission case (3).

18. Use the hoist to carefully remove bearing cage (20) and the shim pack from transmission case (3). The combined weight of the bearing cage and the shim pack is 28 kg (62 lb).
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    Illustration 12	g00594891

19. Install Tooling (D) to output shaft (17). Attach a hoist and suitable lifting slings to Tooling (D).

20. Use the hoist to carefully remove output shaft (17) from transmission case (3). The weight of the output shaft is 29 kg (65 lb).
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    Illustration 13	g00594892

21. Install shaft (2) on Tooling (E), as shown.

22. Remove retaining ring (21) and thrust disc (22) from shaft (2).
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    Illustration 14	g00594895

23. Remove retaining ring (23) from gear (24).

24. Remove gear (24) from shaft (2).
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    Illustration 15	g00594915
    Running Clearance for No. 1 Clutch (Low Forward) (25) End plate. (26) Retaining ring. (27) Oil passage. (X) Running clearance.

25. Use Tooling (F), a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place shaft (2) in the vertical position. End plate (25) that will be measured should be facing upward.

    2. Make sure that end plate (25) is free.

    3. Position the tip of Tooling (F) (not shown) on end plate (25). Zero Tooling (F).
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       Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (27) in the shaft for the clutch that is being checked.

    5. End plate (25) should come into contact with retaining ring (26). When the end plate contacts retaining ring (26) use the dial indicator in order to determine the amount of movement. This is running clearance (X) of the clutch pack.

       Reference: For the proper running clearance, refer to Testing and Adjusting, RENR4335, "Transmission Clutch Running Clearance - Check".

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    Illustration 16	g00594896

26. Remove retaining ring (26) and end plate (25) from shaft (2).
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    Illustration 17	g00594897

27. Remove hub (28) from shaft (2).
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    Illustration 18	g00594901

28. Remove thrust disc (29) and retainer (30) from shaft (2).
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    Illustration 19	g00594903

29. Remove seven friction discs (31) and seven clutch plates (32) (hidden) from shaft (2).
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    Illustration 20	g00594904

30. Remove retaining ring (33) from shaft (2).
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    Illustration 21	g00594905

31. Install Tooling (G) to shaft (2). Use Tooling (G) to compress the wave spring (not shown).

32. Remove retaining ring (34).

33. Release the pressure on the wave spring and remove Tooling (G).
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    Illustration 22	g00594907

34. Remove balance seal assembly (35) from shaft (2).
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    Illustration 23	g00594908

35. Remove wave spring (36) from shaft (2).
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    Illustration 24	g00594912

36. Apply suitable air pressure to passage (27) in order to move piston (37) upward. Remove piston (37) from shaft (2).
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    Illustration 25	g00595075

37. Remove seal rings (38) and (39) from piston (37).
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    Illustration 26	g00594918

38. Turn shaft (2) to the opposite side and install shaft (2) on Tooling (E).

39. Remove three seal rings (40) from shaft (2).
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    Illustration 27	g00594921

40. Remove retaining ring (41), thrust disc (42), and gear (43) from shaft (2).
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    Illustration 28	g00594923
    Running Clearance for No. 2 Clutch (High Forward) (44) Oil passage. (45) End plate. (46) Retaining ring. (X) Running clearance.

41. Use Tooling (F), a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place shaft (2) in the vertical position. End plate (45) that will be measured should be facing upward.

    2. Make sure that end plate (45) is free.

    3. Position the tip of Tooling (F) (not shown) on end plate (45). Zero Tooling (F).
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       Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (44) in the shaft for the clutch that is being checked.

    5. End plate (45) should come into contact with retaining ring (46). When the end plate contacts retaining ring (46), use the dial indicator reading to determine the amount of movement. This is running clearance (X) of the clutch pack.

       Reference: For the proper running clearance, refer to Testing and Adjusting, RENR4335, "Transmission Clutch Running Clearance - Check".

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    Illustration 29	g00594929

42. Remove retaining ring (46) and end plate (45) from shaft (2).
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    Illustration 30	g00594930

43. Remove five friction discs (47) and five clutch plates (48) (hidden) from shaft (2).

44. Remove retaining ring (49) from shaft (2).
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    Illustration 31	g00594932

45. Install Tooling (G) to shaft (2). Use Tooling (G) to compress the wave spring (not shown).

46. Remove retaining ring (50).

47. Release the pressure on the wave spring and remove Tooling (G).
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    Illustration 32	g00594936

48. Remove balance seal assembly (51) from shaft (2).
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    Illustration 33	g00594937

49. Remove wave spring (52) from shaft (2).
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    Illustration 34	g00594938

50. Apply suitable air pressure to passage (44) in order to move piston (53) upward. Remove piston (53) from shaft (2).

51. Remove shaft (2) from Tooling (E).
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    Illustration 35	g00595076

52. Remove seal rings (54) and (55) from piston (53).
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    Illustration 36	g00594939

53. Install shaft (4) on Tooling (E), as shown.
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    Illustration 37	g00594940

54. Remove retaining ring (56) and thrust disc (57) from shaft (4).
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    Illustration 38	g00594944

55. Remove retaining ring (58) from gear (59).

56. Remove gear (59) from shaft (4).
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    Illustration 39	g00594945
    Running Clearance for No. 3 Clutch (Reverse) (60) End plate. (61) Retaining ring. (62) Oil passage. (X) Running clearance.

57. Use Tooling (F), a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place shaft (4) in the vertical position. End plate (60) that will be measured should be facing upward.

    2. Make sure that end plate (60) is free.

    3. Position the tip of Tooling (F) (not shown) on end plate (60). Zero Tooling (F).
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       Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (62) in the shaft for the clutch that is being checked.

    5. End plate (60) should come into contact with retaining ring (61). When the end plate contacts retaining ring (61), use the dial indicator reading to determine the amount of movement. This is running clearance (X) of the clutch pack.

       Reference: For the proper running clearance, refer to Testing and Adjusting, RENR4335, "Transmission Clutch Running Clearance - Check".

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    Illustration 40	g00594950

58. Remove retaining ring (61) and end plate (60) from shaft (4).
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    Illustration 41	g00594951

59. Remove hub (63) from shaft (4).
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    Illustration 42	g00594953

60. Remove thrust disc (64) and retainer (65) from shaft (4).
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    Illustration 43	g00594955

61. Remove seven friction discs (66) and seven clutch plates (67) (hidden) from shaft (4).
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    Illustration 44	g00594956

62. Remove retaining ring (68) from shaft (4).
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    Illustration 45	g00594957

63. Install Tooling (G) to shaft (4). Use Tooling (G) to compress the wave spring (not shown).

64. Remove retaining ring (69).

65. Release the pressure on the wave spring and remove Tooling (G).
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    Illustration 46	g00594958

66. Remove balance seal assembly (70) from shaft (4).
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    Illustration 47	g00594960

67. Remove wave spring (71) from shaft (4).
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    Illustration 48	g00594964

68. Apply suitable air pressure to passage (62) in order to move piston (72) upward. Remove piston (72) from shaft (4).
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    Illustration 49	g00595077

69. Remove seal rings (73) and (74) from piston (72).
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    Illustration 50	g00594965

70. Turn shaft (4) to the opposite side and install shaft (4) on Tooling (E).

71. Remove three seal rings (75) from shaft (4).
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    Illustration 51	g00594966

72. Remove retaining ring (76), thrust disc (77), and the washer from shaft (4).
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    Illustration 52	g00594971

73. Remove gear (78) and spacer (79) from shaft (4).
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    Illustration 53	g00594972

74. Remove retaining ring (80) and gear (81) from shaft (4).
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    Illustration 54	g00594975
    Running Clearance for No. 4 Clutch (Second Speed) (82) Oil passage. (83) End plate. (84) Retaining ring. (X) Running clearance.

75. Use Tooling (F), a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place shaft (4) in the vertical position. End plate (83) that will be measured should be facing upward.

    2. Make sure that end plate (83) is free.

    3. Position the tip of Tooling (F) (not shown) on end plate (83). Zero Tooling (F).
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       Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (82) in the shaft for the clutch that is being checked.

    5. End plate (83) should come into contact with retaining ring (84). When the end plate contacts retaining ring (84), use the dial indicator reading to determine the amount of movement. This is running clearance (X) of the clutch pack.

       Reference: For the proper running clearance, refer to Testing and Adjusting, RENR4335, "Transmission Clutch Running Clearance - Check".

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    Illustration 55	g00594978

76. Remove retaining ring (84) and end plate (83) from shaft (4).
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    Illustration 56	g00595018

77. Remove hub (85) from shaft (4).
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    Illustration 57	g00595019

78. Remove thrust disc (86) and retainer (87) from shaft (4).
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    Illustration 58	g00595020

79. Remove five friction discs (88) and five clutch plates (89) (hidden) from shaft (4).
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    Illustration 59	g00595021

80. Remove retaining ring (90) from shaft (4).
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    Illustration 60	g00595022

81. Install Tooling (G) to shaft (4). Use Tooling (G) to compress the wave spring (not shown).

82. Remove retaining ring (91).

83. Release the pressure on the wave spring and remove Tooling (G).
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    Illustration 61	g00595023

84. Remove balance seal assembly (92) from shaft (4).
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    Illustration 62	g00595024

85. Remove wave spring (93) from shaft (4).
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    Illustration 63	g00595025

86. Apply suitable air pressure to passage (82) in order to move piston (94) upward. Remove piston (94) from shaft (4).

87. Remove shaft (4) from Tooling (E).
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    Illustration 64	g00595080

88. Remove seal rings (95) and (96) from piston (94).
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    Illustration 65	g00595026

89. Install shaft (5) on Tooling (E), as shown.
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    Illustration 66	g00595027

90. Remove retaining ring (97) and thrust disc (98) from shaft (5).
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    Illustration 67	g00595028

91. Remove retaining ring (99) from gear (100).

92. Remove gear (100) from shaft (5).
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    Illustration 68	g00595029
    Running Clearance for No. 5 Clutch (Third Speed) (101) End plate. (102) Retaining ring. (103) Oil passage. (X) Running clearance.

93. Use Tooling (F), a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

    1. Place shaft (5) in the vertical position. End plate (101) that will be measured should be facing upward.

    2. Make sure that end plate (101) is free.

    3. Position the tip of Tooling (F) (not shown) on end plate (101). Zero Tooling (F).
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       Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

    4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (103) in the shaft for the clutch that is being checked.

    5. End plate (101) should come into contact with retaining ring (102). When the end plate contacts retaining ring (102), use the dial indicator reading to determine the amount of movement. This is running clearance (X) of the clutch pack.

       Reference: For the proper running clearance, refer to Testing and Adjusting, RENR4335, "Transmission Clutch Running Clearance - Check".

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    Illustration 69	g00595031

94. Remove retaining ring (102) and end plate (101) from shaft (5).
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    Illustration 70	g00595032

95. Remove hub (104) from shaft (5).
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    Illustration 71	g00595034

96. Remove thrust disc (105) and retainer (106) from shaft (5).
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    Illustration 72	g00595035

97. Remove five friction discs (107) and five clutch plates (108) (hidden) from shaft (5).
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    Illustration 73	g00595037

98. Remove retaining ring (109) from shaft (5).
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    Illustration 74	g00595038

99. Install Tooling (G) to shaft (5). Use Tooling (G) to compress the wave spring (not shown).

100. Remove retaining ring (110).

101. Release the pressure on the wave spring and remove Tooling (G).
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     Illustration 75	g00595040

102. Remove balance seal assembly (111) from shaft (5).
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     Illustration 76	g00595041

103. Remove wave spring (112) from shaft (5).
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     Illustration 77	g00595043

104. Apply suitable air pressure to passage (103) in order to move piston (113) upward. Remove piston (113) from shaft (5).
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     Illustration 78	g00595081

105. Remove seal rings (114) and (115) from piston (113).
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     Illustration 79	g00595045

106. Turn shaft (5) to the opposite side and install shaft (5) on Tooling (E).

107. Remove four seal rings (116) from shaft (5).
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     Illustration 80	g00595046

108. Remove retaining ring (117) and gear (118) from shaft (5).
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     Illustration 81	g00595048

109. Remove thrust disc (119) from shaft (5).
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     Illustration 82	g00595049

110. Remove retaining ring (120) from gear (121).

111. Remove gear (121) from shaft (5).
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     Illustration 83	g00595051

112. Remove hub (122) from shaft (5).
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     Illustration 84	g00595052

113. Remove thrust disc (123) and retainer (124) from shaft (5).
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     Illustration 85	g00595053
     Running Clearance for No. 6 Clutch (First Speed) (125) Oil passage. (126) End plate. (127) Retaining ring. (X) Running clearance.

114. Use Tooling (F), a suitable air supply, and the following procedure to measure the running clearance of the clutch pack:

     1. Place shaft (5) in the vertical position. End plate (126) that will be measured should be facing upward.

     2. Make sure that end plate (126) is free.

     3. Position the tip of Tooling (F) (not shown) on end plate (126). Zero Tooling (F).
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        Personal injury can result from applying air pressure without the lock ring securely in place. If the lock ring is not secure, the end plate and discs can suddenly come out with great force. Make sure lock ring is securely in place before applying air pressure to clutch pack.

     4. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (125) in the shaft for the clutch that is being checked.

     5. End plate (126) should come into contact with retaining ring (127). When the end plate contacts retaining ring (127), use the dial indicator reading to determine the amount of movement. This is running clearance (X) of the clutch pack.

        Reference: For the proper running clearance, refer to Testing and Adjusting, RENR4335, "Transmission Clutch Running Clearance - Check".

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     Illustration 86	g00595056

115. Remove retaining ring (127) and end plate (126) from shaft (5).

116. Remove eight friction discs (128) (hidden) and eight clutch plates (129) (hidden) from shaft (5).
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     Illustration 87	g00595058

117. Remove retaining ring (130) from shaft (5).
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     Illustration 88	g00595059

118. Install Tooling (G) to shaft (5). Use Tooling (G) to compress the wave spring (not shown).

119. Remove retaining ring (131).

120. Release the pressure on the wave spring and remove Tooling (G).
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     Illustration 89	g00595061

121. Remove balance piston (132) from shaft (5).
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     Illustration 90	g00595063

122. Remove wave spring (133) from shaft (5).
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     Illustration 91	g00595064

123. Apply suitable air pressure to passage (125) in order to move piston (134) upward. Remove piston (134) from shaft (5).
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     Illustration 92	g00595066

124. Remove seal rings (135) and (136) from piston (134).
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     Illustration 93	g00595067

125. Use a press to remove seal carrier (137), roller bearing cone (138), and gear (139) from input shaft (1).
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     Illustration 94	g00595070

126. Remove seal ring (140) from input shaft (1).

127. Remove two metal seal rings (141) from seal carrier (137).
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     Illustration 95	g00595071

128. Use a press to remove roller bearing cone (142) and gear (143) from input shaft (1).
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     Illustration 96	g00595073

129. Use a press to remove roller bearing cone (144) and gear (145) from output shaft (17).