TA19 Transmission Caterpillar

Disassembly Procedure

1. Position the transmission onto suitable cribbing. The weight of the transmission is approximately 1316 kg (2900 lb).

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Illustration 1	g02359576

2. Remove bolts (1) and (2) .

3. Disconnect harness assembly (3) and position the harness assembly out of the way. Remove the input speed sensor.

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Illustration 2	g02363056

4. Remove bolt (5), retainer (6), and yoke (7). Remove O-ring seal (4) (not shown).

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Illustration 3	g02387596

5. Yoke (11) is located on the opposite side. Remove bolt (9), retainer (10), and yoke (11). Remove O-ring seal (8) (not shown).

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Illustration 4	g02686661

6. Attach Tooling (A) and a suitable lifting device to Locations (X). Remove the bolts for cover assembly (12). The weight of cover assembly (12) is approximately 59 kg (130 lb).

7. Use Tooling (D) to break the seal between the case assembly and cover assembly (12). The holes for inserting Tooling (D) are at Locations (X). Remove bolts (13) and remove cover assembly (12) .

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Illustration 5	g02440256

8. Remove tube assembly (14) and remove bolts (15) .

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Illustration 6	g02440277

9. Use Tooling (B) in order to remove bearing cage (16). Remove shims (17) (not shown).

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Illustration 7	g02440336

10. Remove O-ring seal (20) and remove bearing cup (18) .

11. Remove lip seal (19). Use Tooling (C) and a suitable press if necessary.

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Illustration 8	g02440536

12. Remove bolt (21), retainer (22), and remove gear (23) .

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Illustration 9	g02440477

13. Attach Tooling (D) and a suitable lifting device to shaft assembly (24). The weight of shaft assembly (24) is approximately 75 kg (165 lb). Remove shaft assembly (24) .

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Illustration 10	g02440697

14. Mark the location of bearing cage (27) for assembly purposes. Remove bolts (26). Use Tooling (E) in order to remove bearing cage (27). Remove shims (25) (not shown).

15. Repeat Step 14 for the other bearing cages.

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Illustration 11	g02440722

16. Remove bolt (29). Remove tube assembly (28) and the O-ring seals.

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Illustration 12	g02440726

17. Attach Tooling (A) and a suitable lifting device to case (31). Remove bolts (30) and (32). The weight of case assembly (31) is approximately 365 kg (805 lb). Remove case (31). Position case (31) on suitable cribbing and position the case so that the gasket surface if facing up.

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Illustration 13	g02441421

18. Remove O-ring seals (33) .

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Illustration 14	g02442156

Note: Do not remove bolts (X) .

19. Remove bolts (34). Use two people in order to remove clutch assembly (35). The weight of clutch assembly (35) is approximately 25 kg (55 lb).

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Illustration 15	g02515337

20. Use Tooling (C) in order to remove bearing cup (36) from case assembly (31) .

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Illustration 16	g02442526

21. Remove O-ring seals (37) from clutch assembly (35) .

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Illustration 17	g02442527

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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.

22. Remove bolts (38). Remove reaction plate (39) and ring gear (40) .

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Illustration 18	g02442528

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Illustration 19	g02442529

23. Remove disc (41) and plates (42). Remove springs (43) and remove dowels (44) from housing (45), if necessary.

24. Remove piston (47) from the housing. Remove seals (46) and (48) from piston (47) .

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Illustration 20	g02440856

25. Yoke (51) is located on the opposite side of the transmission. Remove bolt (50), remove retainer (49), and remove yoke (51) .

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Illustration 21	g02516016

26. Attach Tooling (F) and a suitable lifting device to shaft assemblies (52). The weight of shaft assemblies (52) is approximately 375 kg (820 lb). Remove shaft assemblies (52) .

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Illustration 22	g01269519

27. Remove ring seals (53) .

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Illustration 23	g02516856

28. Place the shaft assemblies onto Tooling (G). Remove Tooling (F) .

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Illustration 24	g02516116
Reverse shaft

29. Use Tooling (H) in order to remove bearing cone (54) from shaft assembly (55) .

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Illustration 25	g01269685

30. Remove bearing cone (54), spacer (56), spacer (57), gear (58), and spacer (59) from shaft assembly (55) .

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Illustration 26	g01269743

31. Rotate shaft assembly (55) by 180 degrees. Remove bolts (60) and remove seal carrier (61) .

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Illustration 27	g02516537

32. Use Tooling (H) in order to remove bearing cone (62) .

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Illustration 28	g01269751

33. Remove bearing cone (62) and spacer (63). Remove thrust washer (64) and gear (65) .

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Illustration 29	g01269758

34. Remove bearings (66) and thrust washer (67). Use Tooling (J) in order to remove retaining ring (68). Remove clutch plate (69). Remove the friction discs and plates (70) from shaft assembly (55) .

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Illustration 30	g02516957

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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.

35. Use a suitable press and Tooling (K) in order to compress spring (72). Remove retaining ring (71) .

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Illustration 31	g01269767

36. Remove spacer (73), seal assembly (74), and spring (75) from shaft assembly (55) .

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Illustration 32	g01270206

37. Remove piston (77) from shaft assembly (55). Remove seals (76) from piston (77) and shaft assembly (55). Remove seal (78) from piston (77) .

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Illustration 33	g02516540
Intermediate Shaft

38. Use Tooling (H) in order to remove bearing cone (79) from shaft assembly (80) .

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Illustration 34	g01270211

39. Remove bearing cone (79), spacer (81), spacer (82), thrust washer (83), and gear (84) from shaft assembly (80). Remove bearings (85) and thrust washer (83) .

    Note: The procedure for the disassembly of the clutch packs will be identical.

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Illustration 35	g01269959

40. Rotate shaft assembly (80) by 180 degrees. Remove bolts (86) and seal carrier (87). Remove bearing cone (88) from shaft assembly (80) .

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Illustration 36	g02516576

41. Use Tooling (H) in order to remove bearing cone (89) from shaft assembly (80) .

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Illustration 37	g01269968

42. Remove bearing cone (89), spacer (90), spacer (91), and gear (92) from shaft assembly (80) .

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Illustration 38	g01269969

43. Remove gear (93), spacer (94), thrust washer (95), and gear (96). Remove bearing (97) and thrust washer (95) from shaft assembly (80) .

    Note: The procedure for the disassembly of the clutch packs will be identical.

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Illustration 39	g02516597
Output Shaft

44. Use Tooling (H) in order to remove bearing cone (98) from shaft assembly (99) .

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Illustration 40	g01269976

45. Remove bearing cone (98), spacer (100), and planetary carrier (101) from shaft assembly (99) .

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Illustration 41	g01269978

Note: Drive spring pin (105) into shaft (106) until shaft (106) can be removed. Do not drive spring pin (105) too far.

46. Drive spring pin (105) into shaft (106). Remove shaft (106), thrust discs (102), gear (104), and bearings (103) from carrier (101) .

47. Remove spring pin (105) and the cup plug from shaft (106) .

Note: The procedure for the disassembly of the planetary carriers will be identical.

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Illustration 42	g01269983

48. Remove thrust washer (107), sun gear (108), spacer (109), thrust washer (110), and gear (111). Remove bearings (112) and thrust washer (110) from shaft assembly (99) .

    Note: The procedure for the disassembly of the clutch packs will be identical.

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Illustration 43	g01269986

49. Rotate shaft assembly (99). Remove bolts (113), seal carrier (114), bolts (115), and rotor (116) from shaft assembly (99) .

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Illustration 44	g02516619

50. Use Tooling (H) to remove bearing cone (117) from shaft (99) .

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Illustration 45	g01270067

51. Remove bearing cone (117), spacer (118), and planetary carrier (119) from shaft assembly (99) .

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Illustration 46	g01270078

52. Remove thrust washer (120), sun gear (121), tube (122), thrust washers (123), and gear (124). Remove bearings (125) and spacer (126) from shaft assembly (99) .

    Note: The procedure for the disassembly of the clutch packs will be identical.

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Illustration 47	g02516656
Input Shaft

53. Use Tooling (H) in order to remove bearing cone (127) from shaft assembly (128) .

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Illustration 48	g01270092

54. Remove bearing cone (127), spacer (129), spacer (130), gear (131), and gear (132) from shaft assembly (128) .

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Illustration 49	g01270098

55. Remove spacer (133), thrust washer (134), and gear (135). Remove bearings (136) and thrust washer (134) from shaft assembly (128) .

    Note: The procedure for the disassembly of the clutch packs will be identical.

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Illustration 50	g02516676

Note: Remove the seal rings before removal of bearing cone (137) .

56. Rotate shaft assembly (128) by 180 degrees. Use Tooling (H) in order to remove bearing cone (137) from shaft assembly (128) .

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Illustration 51	g01270555

57. Remove bearing cone (137), spacer (138), thrust washer (139), and gear (140). Remove bearings (141) and thrust washer (139) from shaft assembly (128) .

    Note: The procedure for the disassembly of the clutch packs will be identical.

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Illustration 52	g01329472

Note: Do not remove bolts (Y) .

58. Remove bolts (142). Use two people in order to remove clutch assembly (143). The weight of clutch assembly (143) is approximately 25 kg (55 lb).

59. Refer to Steps 21 through 23 for disassembly of remaining clutch assemblies.

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Illustration 53	g01270596

60. Remove bearing cups (144) .

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Illustration 54	g02454098

61. Remove bolts (145) and seal ring housing (146) .

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Illustration 55	g01270632

62. Remove O-ring seals (147) from seal ring housing (146) .

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Illustration 56	g01270685

63. Remove lip seal (148) from seal ring housing (146) .