69D and 769D Off-Highway Truck and 771D Quarry Truck Power Train Caterpillar

Rear Axle Housing and Differential - Remove

Usage:

769D 5SS

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A⁽¹⁾	9U-7536	Lift Stand	2
	447-0910	Electric Hydraulic Pump Gp (115V)	1
	447-0911	Electric Hydraulic Pump Gp (230V)	1
A1	OR
	504-9791	Lift Gp (60Hz)⁽²⁾	2
	504-9793	Lift Gp (50Hz)⁽³⁾	2
B	FT-1332	Support Bracket	1
C	444-0526	Hydraulic Jack	1
D	4C-4892	Fitting Kit	1
D	7H-1680	Lubrication Pump	1

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⁽¹⁾	Use Tooling (A) or (A1) based on requirements.
⁽²⁾	Operating-Voltage (480V - 240V)
⁽³⁾	Operating-Voltage (400V- 200V)

Start By:

Remove the body and canopy.
Remove the rear suspension (cylinders).
Remove the lateral control rod (rear axle housing).
Remove the rear drive shaft.

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, PERJ1017, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat^® products. Dispose of all fluids according to local regulations and mandates.

Drain the rear axle housing. Refer to Operation and Maintenance Manual, SEBU7092, "Differential and Final Drive Oil - Change".
Drain the hydraulic tank (hoist and brake). Refer to Operation and Maintenance Manual, SEBU7092, "Hoist and Brake Tank Oil - Change".
Install caps and plugs on all openings to prevent dirt or debris from entering the system. Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will prevent dirt from entering the internal mechanism.
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Illustration 1 g00578503
Position a suitable container below hose assembly (1) and (2) to contain hydraulic oil for storage or disposal. Disconnect hose assemblies (1) and (2).
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Illustration 2 g00578506
Position a suitable container below hose assembly (3) and (4) to contain hydraulic oil for storage or disposal. Disconnect hose assemblies (3) and (4).
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Illustration 3 g00578510
Remove lock wire (6). Disconnect wire harness (5) from the speed sensor. Remove all the nuts, the bolts, and the clips that hold wire harness (5) to the rear axle housing. Position wire harness (5) out of the way.
Repeat Step 6 for the remaining speed sensor. The speed sensor is on the other end of the rear axle housing.
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Illustration 4 g00578641
Loosen the four top bolts (7) on bolster cap (8).
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Illustration 5 g00578663

For Tooling (A)
Use Tooling (A) to raise the frame assembly above the rear axle housing.
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Illustration 6 g06403045

For Tooling (A1)
Use Tooling (A1) to raise the frame assembly above the rear axle housing. Refer to Tool Operating Manual, NEHS1303, "Lift Group (Stand - 25 Ton)" for more information on Tooling (A1).
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Illustration 7 g00578699
Attach Tool (B) to the rear axle housing, as shown. Position Tool (C) under the rear axle housing, as shown. Apply pressure to the front of the rear axle housing with Tool (C).
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Illustration 8 g00578703
Remove eight bolts (7) and the hard washers from bolster cap (8).
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Illustration 9 g00578710

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NOTICE

To avoid damage to the braking system, do not exceed 3150 kPa (460 psi) when applying pressure to release the parking brake.
Fasten Tooling (D) (not shown) to the rear service and parking brake to release the parking brake.
Attach two suitable lifting slings to rear axle housing (9). Attach the two lifting slings to a suitable lift truck. Pull rear axle housing (9) from the frame assembly.
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Illustration 10 g00578999

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Illustration 11 g00579006
If necessary, remove stake nut (10). Remove kingbolt (11) and bolster cap (12) from the support assembly. Illustrations 10 and 11 show the 775D Off Highway Truck. The procedure for the 771D Off Highway Truck is identical. The weight of kingbolt (11) is 39 kg (86 lb). The weight of bolster cap is 12 kg (26 lb).
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Illustration 12 g00578993
Remove two bolts (13) and the washers. Remove ball socket (14) from the frame assembly. The weight of ball socket is 29 kg (64 lb).