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

Disassembly Procedure

Start By:

1. Remove differential and bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Remove".

Show/hide table

Illustration 1	g00490481

1. Position the differential and bevel gear on Tooling (A). The weight of the differential and bevel gear is approximately 399 kg (880 lb).

2. Remove locking bolt (2), the washer and the lock.

3. Use Tooling (B) (not shown) in order to loosen adjustment ring (4) from each side of the differential.

4. Remove bolts (1) and the washers. Remove bearing caps (3).
   Show/hide table

   Illustration 2	g00490492

5. Install a bar (X) through the differential, as shown. Attach a suitable lifting device to bar (X). Remove the differential from the differential carrier (6). The weight of differential carrier (6) is approximately 197 kg (435 lb).

6. Remove adjustment ring (4) and bearing cage (5) from each side of the differential.
   Show/hide table

   Illustration 3	g00490495

7. Use Tooling (C) in order to remove roller bearing cone (7) from each side of differential housing assembly (8).
   Show/hide table

   Illustration 4	g00490497

8. Put an alignment mark on housing (9) and differential housing assembly (8) for assembly purposes. Position a suitable lifting device around the differential, as shown.

9. Remove bolts (10), the nuts and the washers that hold housing (9) to differential housing assembly (8). Remove housing (9) and the differential ring gear from differential housing assembly (8). The weight of housing (9) and the differential ring gear is approximately 82 kg (180 lb).
   Show/hide table

   Illustration 5	g00490498

10. Remove bolts (11) and housing (9) from differential ring gear (12). The weight of housing (9) is approximately 41 kg (90 lb). The weight of differential ring gear (12) is approximately 41 kg (90 lb).
    Show/hide table

    Illustration 6	g00490499

11. Remove thrust washer (14) and differential bevel gear (13).
    Show/hide table

    Illustration 7	g00490520

12. Position a suitable lifting sling around differential spider gear (16). Attach the lifting sling to a suitable hoist. Remove differential spider gear (16) and differential pinions (15) as an assembly from differential housing assembly (8). The weight of differential spider gear (16) and differential pinions (15) is approximately 36 kg (80 lb).
    Show/hide table

    Illustration 8	g00577704

13. Remove differential pinions (15) from differential spider gear (16).

14. Use the following procedure to disassemble the spider and pinion assembly.
    Show/hide table

    Illustration 9	g00577708

15. Position Tooling (D) in a suitable vise. Install differential pinion (15) on Tooling (D), as shown.

    Note: Be sure that groove (17) is in alignment with dowel (18).

    Show/hide table

    Illustration 10	g00577709

    Note: Nut (19) is part of Tooling (D).

16. Install nut (19) to Tooling (D), as shown.
    Show/hide table

    Illustration 11	g00577712

17. Use a hammer and a brass drift in order to bend the tabs on nut lock (20). Remove nut (19).
    Show/hide table

    Illustration 12	g00577734

18. Use Tooling (E) to remove nut (21) (not shown).
    Show/hide table

    Illustration 13	g00577735

19. Remove nut lock (20).
    Show/hide table

    Illustration 14	g00577737

    Show/hide table

    Illustration 15	g00577740

20. Remove differential pinion (15) and roller bearing assembly (22). Remove roller bearing assembly (22) from differential pinion (15).
    Show/hide table

    Illustration 16	g00577743

21. Remove retainer (23) and roller bearing assembly (24) from Tooling (D).

22. Repeat Steps 15 through 21 for the remaining differential bevel pinions.
    Show/hide table

    Illustration 17	g00490523

23. Remove differential bevel gear (13) and thrust washer (14) from differential housing assembly (8).

24. Remove bolts (10).
    Show/hide table

    Illustration 18	g01030364

25. Install Tooling (F) and a suitable lifting device to differential carrier assembly (25). Position differential carrier assembly (25) on Tooling (G). The weight of the differential carrier assembly (25) is approximately 186 kg (410 lb).
    Show/hide table

    Illustration 19	g00490525

26. Remove locking bolt (27), the hard washer, collar (28) and yoke (26) from the pinion.
    Show/hide table

    Illustration 20	g00490526

27. Remove O-ring seal (30) from pinion (29).
    Show/hide table

    Illustration 21	g00490527

28. Remove the remaining five bolts (32) that hold bearing cage (31) to differential carrier assembly (25). Install two 1/2 inch - 13 NC forcing bolts in bearing cage (31). Tighten the forcing bolts evenly. Remove bearing cage (31) and the shims from differential carrier assembly (25).
    Show/hide table

    Illustration 22	g00490528

29. Remove lip seal (34) from bearing cage (31). Remove roller bearing cup (33) and O-ring seal (35) from bearing cage (31).
    Show/hide table

    Illustration 23	g01030367

30. Install Tooling (H) and a suitable lifting device to pinion (36). Remove pinion (36) from differential carrier assembly (25). The weight of pinion (36) is approximately 32 kg (70 lb).
    Show/hide table

    Illustration 24	g00490531

31. Use Tooling (C) (not shown) in order to remove roller bearing cones (37) and (38) from pinion assembly (36).
    Show/hide table

    Illustration 25	g00490532

32. Remove roller bearing cup (39) from differential carrier assembly (25).