G3500 Engines Caterpillar

Disassembly Procedure

Start By:

1. Remove the air starting motor. Refer to Disassembly and Assembly, "Air Starting Motor - Remove".

Note: The individual parts of the air starting motor are nonserviceable. An overhaul kit must be purchased in order to service the air starting motor.

1. Mark all the adjacent parts of the housing for the air starting motor for assembly purposes.
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   Illustration 1	g01170823

2. Remove bolts (1) and remove drive housing (2) from gearbox housing (3).
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   Illustration 2	g01170843

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   Illustration 3	g01171324

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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.

   Note: When bolt (4) is removed spring tension will be released from drive assembly (7).

3. Position drive housing (2) into a suitable press. Remove bolt (4) and washer (5). Remove pinion gear (6). Slowly release the suitable press in order to release the spring tension on drive assembly (7).
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   Illustration 4	g01170867

4. Remove drive assembly (7), spring (8), and washer (9) from drive housing (2).
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   Illustration 5	g01171383

5. Use Tooling (A) and remove retaining ring (10) from drive assembly (7).
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   Illustration 6	g01171410

6. Use Tooling (B), Tooling (C), and a suitable press in order to remove bearing (11) from drive assembly (7).
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   Illustration 7	g01171415

7. Remove spacer (12). Remove lip seal (13).
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   Illustration 8	g01171417

8. Use Tooling (C) and a suitable press in order to remove spur gear (14) from drive housing (2).
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   Illustration 9	g01171422

9. Use Tooling (D) to remove retaining ring (15). Use Tooling (E) to remove retaining ring (16).
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   Illustration 10	g01171531

10. Use Tooling (C) and a suitable press in order to remove bearing (17).
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    Illustration 11	g01171424

11. Use Tooling (F), Tooling (C), and a suitable press in order to remove bearing (18) from spur gear (14).
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    Illustration 12	g01171533

12. If necessary, remove bearing (19) from drive housing (2).
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    Illustration 13	g01171573

13. Remove bolts (20) and remove gearbox housing (3).
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    Illustration 14	g01171575

14. Remove ring gear (21).
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    Illustration 15	g01171580

15. Remove allen head bolts (22).
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    Illustration 16	g01171591

16. Remove planetary assembly (23). Remove O-ring seal (24).
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    Illustration 17	g01171739

17. Bend the tab of lock washer (26) out of slot in spanner nut (25).
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    Illustration 18	g01171744

18. Position planetary assembly (23) into a soft jawed vise. Use Tooling (G) and remove spanner nut (25).
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    Illustration 19	g01171752

19. Remove lock washer (26). Remove spur gear (27) and the woodruff key.
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    Illustration 20	g01171762

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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.

20. Use a suitable press and remove planetary carrier assembly (29) from bearing housing (28).
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    Illustration 21	g01171769

21. Use Tooling (D) and remove retaining ring (30) from bearing housing (28). Remove bearing (31).
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    Illustration 22	g01171772

22. Remove spacer (32), washer (33), and spring washers (34).
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    Illustration 23	g01171774

23. Use Tooling (H) and a suitable press in order to remove bearing (35) from planetary carrier assembly (29).
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    Illustration 24	g01171808

24. Use Tooling (A) and remove retaining ring (36).
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    Illustration 25	g01171812

25. Remove pin (39), thrust washers (37), and planetary gear (38).
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    Illustration 26	g01171983

26. Use Tooling (C) and a suitable press in order to remove bearing (40) from planetary gear (38).

27. Repeat Step 24 through Step 26 for the remaining planetary gears.
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    Illustration 27	g01171986

28. Remove allen head bolts (41). Remove housing (42).
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    Illustration 28	g01171989

29. Remove O-ring seal (43) from housing (42).
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    Illustration 29	g01171998

30. Remove allen head bolt (44) and the washer. Remove rotor (45) and the woodruff key.
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    Illustration 30	g01172022

31. Remove spacer (46). Remove allen head bolts (47).
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    Illustration 31	g01172024

32. Remove allen head bolts (48) and retainer plate (49).
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    Illustration 32	g01172168

33. Use a suitable press and remove turbine shaft (50).
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    Illustration 33	g01172209

34. Remove spacer (51) and bearing (52) from turbine shaft (50).
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    Illustration 34	g01172212

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    Illustration 35	g01173007

35. Remove housing (53) and O-ring seal (54). Remove spacer (55), rotor (56), and the woodruff key (not shown).
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    Illustration 36	g01172585

36. Remove allen head bolts (57) and remove nozzle (58).
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    Illustration 37	g01172614

37. Remove O-ring seal (59).
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    Illustration 38	g01172618

38. Use Tooling (C) and remove lip seal (60) from nozzle (58).
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    Illustration 39	g01172599

39. Remove spacer (61).
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    Illustration 40	g01172613

40. Use Tooling (C) and a suitable press. Press through lip seal (62) in order to remove bearing (63) (not shown).
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    Illustration 41	g01172628

41. Remove wave washer (64). Use Tooling (C) and a suitable press and remove lip seal (62).