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

Disassembly Procedure

Start By:

1. Separate the transmission planetary from the transfer gears. Refer to Disassembly and Assembly, "Transmission Planetary and Transfer Gears - Separate".

2. Remove the transmission hydraulic control. Refer to Disassembly and Assembly, "Transmission Hydraulic Control - Remove".

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Illustration 1	g03325842

1. Put the transmission in position on Tool (A). The weight of the transmission is 816 kg (1800 lb). Remove the six bolts, the washers, and the spacer from bracket (3). Remove bracket (3).

2. Attach Tooling (B) and a suitable lifting device to transmission planetary (1). Remove 25 bolts (2) that hold transmission planetary (1) to case (4). Remove transmission planetary (1) and the O-ring seal from case (4). The weight of transmission planetary (1) is 610 kg (1350 lb).

3. Remove case (4) from Tool (A). The weight of case (4) is 205 kg (450 lb).
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   Illustration 2	g03325864

4. Install the transmission planetary on Tool (A).
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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.

5. Attach Tooling (K) and a suitable lifting device to clutch housing assembly (7). Put identification on bolts (6) for assembly purposes. Remove eight bolts (6) and the washers that hold clutch housing assembly (7) to the transmission planetary. Remove clutch housing assembly (7). The weight of the clutch housing assembly is 50 kg (110 lb).
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   Illustration 3	g03325903

6. Remove the eight bolts and the washers that hold manifold (8) to clutch housing assembly (7). Lift clutch housing assembly (7) off manifold (8). The weight of clutch housing assembly (7) is 30 kg (70 lb).
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   Illustration 4	g00491403

7. Remove four bolts, the washers, and manifold (8) from bearing cage (9).
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   Illustration 5	g00491404

8. Use Tool (C) (not shown) to remove retaining ring (10) from clutch hub assembly (11).

9. Install two 3/8 inch - 16 NC forcing screws in bearing cage (9). Tighten the forcing screws evenly. Remove bearing cage (9) and the ball bearing from clutch hub assembly (11).
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   Illustration 6	g00491405

10. Use Tooling (D) (not shown) to remove ball bearing (12) from bearing cage (9).
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    Illustration 7	g00491406

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    Illustration 8	g00491407

11. Remove retainer ring (13), as shown. Retainer ring (13) holds sun gear (14) to clutch hub assembly (11). Remove sun gear (14) from clutch hub assembly (1).
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    Illustration 9	g00491408

12. Remove clutch piston (15). Remove the seal from clutch piston (15).

13. Remove ten springs (17) and five dowels (16).
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    Illustration 10	g00491409

14. Remove two friction disc assemblies (19) and clutch plate (18).
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    Illustration 11	g03325936

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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.

15. Use Tooling (E) to hold the clutch piston in clutch housing (20). Attach Tooling (K) and a suitable lifting device to clutch housing (20). Remove clutch housing (20). The weight of clutch housing (20) and the clutch piston as a unit is 28 kg (61.7 lb).
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    Illustration 12	g00491411

16. Remove clutch piston (21) from clutch housing (20). Remove the ring seal and the seal extension ring from clutch piston (21).
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    Illustration 13	g00491412

17. Remove ten springs (23) and five reaction dowels (22) from the plate assembly.

18. Remove three friction discs (24) and two clutch plates (25).
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    Illustration 14	g00491413

19. Install Tooling (B) (not shown) to plate assembly (28). Attach a suitable lifting device to Tooling (B). Secure the lifting device to a hoist. Remove ring gear (26) and plate assembly (28). If necessary, remove pins (27) from plate assembly (28).
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    Illustration 15	g03325993

20. Invert the transmission planetary. Install the transmission planetary on Tool (A) (not shown). The weight of the transmission planetary is 520 kg (1150 lb).
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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.

21. Attach Tooling (F) and a suitable lifting device to end plate (29). Put identification on bolts (30) for assembly purposes. Remove 20 bolts (30) and the washers that hold end plate (29) to the housing assembly. Remove end plate (29). The weight of end plate is (29) 70 kg (155 lb).
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    Illustration 16	g00491415

22. Position end plate (29), as shown. Remove 12 twelve point head bolts (31) that hold retainer plate (32) to the yoke. Remove retainer plate (32) and the shim pack. The weight of end plate (29) is 48 kg (105 lb).
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    Illustration 17	g00491416

23. Position end plate (29), as shown. Remove yoke assembly (33) from end plate (29). Remove eight bolts (34) and the washers that hold the bearing retainer to end plate (29). The weight of end plate (29) is 48 kg (105 lb).
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    Illustration 18	g00491417

24. Install two 3/8 inch - 16 NC forcing screws (35) in bearing retainer (36). Tighten the forcing screws evenly. Remove bearing retainer (36) and the O-ring seal from end plate (29). Use Tooling (D) (not shown) in order to remove lip seal (37) from bearing retainer (36).
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    Illustration 19	g00491418

25. Remove roller bearing assembly (38) and spacer (39) from end plate (29).
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    Illustration 20	g00491419

26. Remove bearing cup (41) and roller bearing assembly (40) from end plate (29).
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    Illustration 21	g00491420

27. Remove ten springs (44) and five dowels (45) from the clutch housing assembly.

28. Remove ring gear (42), five friction discs (43), and four plates (46) from the clutch housing assembly.
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    Illustration 22	g03326053

29. Attach Tooling (L) and a suitable lifting device to planetary carrier (50). Support the weight of planetary carrier (50). Use Tool (G) in order to remove retaining ring (48).

30. Remove the 4 twelve point head bolts that hold speed adapter (47) to the planetary carrier. Remove speed adapter (47).

31. Remove planetary carrier (50) from the transmission planetary. The weight of planetary carrier (50) is 24 kg (53 lb).
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    Illustration 23	g00491424

32. Use a hammer and a punch to drive spring pin (52) into shaft assembly (51).
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    Illustration 24	g00491848

33. Remove shaft assembly (51) from planetary carrier (50). Remove spring pin (52) from shaft assembly (51).

34. Remove planetary gear (56), two bearings (53), thrust disc (54), and thrust disc (55) from planetary carrier (50).

35. Repeat Steps 32 through 34 for the remaining four gears.
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    Illustration 25	g00491853

36. Remove metal seal ring (58) from carrier assembly (57).
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    Illustration 26	g00491855

37. Remove clutch piston (60) from clutch housing assembly (59). Remove the ring seal and the seal extension ring from the clutch piston.
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    Illustration 27	g03326258

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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.

38. Attach Tooling (K) and a suitable lifting device to clutch housing assembly (59). Remove clutch housing assembly (59) from the transmission planetary. The weight of clutch housing assembly (59) is 23 kg (51 lb).

39. If necessary, remove dowels (61) from the clutch housing assembly.
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    Illustration 28	g00491857

40. Remove ten springs (63) from the clutch piston.

41. Remove four friction discs (62) and three clutch plates (64).
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    Illustration 29	g00491858

42. Use a screwdriver to remove retaining ring (67). Remove sun gear (65) and coupling hub (66) as an assembly.

43. Remove the lock ring that holds sun gear (65) in coupling hub (66).
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    Illustration 30	g03326302

44. Remove 4 twelve point head bolts that hold carrier assembly (57) to the retainer plate. Attach Tooling (M) and a suitable lifting device to carrier assembly (57). The weight of carrier assembly (57) is 25 kg (55 lb).
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    Illustration 31	g00491866

45. Remove bearing (68) from carrier assembly (57).
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    Illustration 32	g00491870

46. Use a hammer and a punch to drive spring pin (70) into shaft assembly (69).
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    Illustration 33	g00491873

47. Remove shaft assembly (69) from the carrier assembly. Remove spring pin (70) from the shaft.

48. Remove planetary gear (74), two bearings (71), thrust disc (72), and thrust disc (73) from the carrier assembly.

49. Repeat Steps 46 through 48 for the remaining three gears.
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    Illustration 34	g00491874

50. Use Tool (C) (not shown) to remove retaining ring (75). Remove sun gear (76).
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    Illustration 35	g00491876

51. Install two 3/8 inch - 16 NC forcing screws in retainer plate (79). Tighten forcing screws (77) evenly. Remove retainer plate (79) and ball bearing (78) as an assembly.
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    Illustration 36	g00491900

52. Remove ball bearing (78) and metal seal ring (80) from retainer plate (79).
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    Illustration 37	g00491907

53. Put identification on bolts (81) for assembly purposes. Remove six bolts (81) and plate (82).
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    Illustration 38	g00491909

54. Use a screwdriver to remove retaining ring (83) from ring gear (84). Remove ring gear (84).

55. Remove clutch piston (85). Remove the ring seal and the seal extension ring from clutch piston (85).
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    Illustration 39	g03326362

56. Attach Tooling (F) and a suitable lifting device to clutch housing assembly (87). Remove clutch housing assembly (87). If necessary, remove two dowels (86) from the clutch housing assembly (87).
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    Illustration 40	g03326400

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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.

57. Use Tooling (E) to hold the clutch piston in clutch housing (88). Attach Tooling (B) and a suitable lifting device to clutch housing (88). Remove clutch housing (88). The weight of clutch housing (88) and the clutch piston is 24 kg (53 lb).
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    Illustration 41	g00491916

58. Remove clutch piston (89) from clutch housing (88). Remove the ring seal and the seal extension ring from clutch piston (89).
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    Illustration 42	g00491920

59. Remove ten springs (93) and five dowels (91) from the plate assembly.

60. Remove two friction discs (90) and plate (92).
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    Illustration 43	g00491923

61. Remove ring gear (96) and plate assembly (94). If necessary, remove two pins (95) from the plate.
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    Illustration 44	g03326430

62. Remove 15 bolts (97) and the washers that hold carrier assembly (98) to the housing assembly. Attach Tooling (M) and a suitable lifting device to carrier assembly (98). Remove the carrier assembly (98).
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    Illustration 45	g00491928

63. Use a hammer and a brass punch in order to drive spring pin (100) in planetary shaft (99).
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    Illustration 46	g00491930

64. Remove planetary shaft (99) from carrier assembly (98). Remove spring pin (100) from planetary shaft (98).

65. Remove planetary gear (102), bearing (101), thrust disc (103), and thrust disc (104) from carrier assembly (98).

66. Repeat Steps 63 through 65 in order to remove all planet gears from the carrier assembly.

67. If necessary, remove the dowels from the carrier assembly.
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    Illustration 47	g00491932

68. Remove metal seal ring (106) from sun gear assembly (105). Remove sun gear assembly (105) from the transmission planetary.
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    Illustration 48	g00491933

69. Remove metal seal ring (107) from the manifold.

70. Remove the two clutch plates and two friction discs (108) from the housing.
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    Illustration 49	g00491938

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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.

71. Remove the three bolts that hold balance piston (109). Install two 3/8 inch - 16 NC forcing screws in balance piston (109). Tighten the forcing screws evenly. Remove balance piston (109) and the ball bearing as an assembly from housing assembly (110).
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    Illustration 50	g00491945

72. Remove ring (113) from balance piston (109). Use Tool (H) (not shown) to remove retaining ring (111). Remove ball bearing (112) from the balance piston.
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    Illustration 51	g03326898

73. Remove 16 retainer springs (114) from the clutch piston.

74. Attach Tooling (N) and a suitable lifting device to housing (110). Remove the housing assembly and the clutch piston as a unit. The weight of the housing assembly and the clutch piston is 26 kg (57 lb).
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    Illustration 52	g00491951

75. Install two 3/8 inch - 16 NC forcing screws in clutch piston (115). Tighten the forcing screws evenly. Remove the clutch piston (115) from housing assembly (110).
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    Illustration 53	g00491952

76. Remove seal extension ring (116) from the clutch piston. Remove seal ring (117) from the housing assembly.
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    Illustration 54	g00491953

77. Remove the bolts that hold manifold assembly (118) to the center manifold. Install two 3/8 inch - 16 NC forcing screws in the manifold assembly. Tighten the forcing screws evenly. Remove manifold assembly (118).
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    Illustration 55	g00491954

78. Remove two seal rings (119) from manifold assembly (118).
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    Illustration 56	g03327058

79. Remove the transmission planetary from Tool (A) (not shown). Position the transmission planetary on the floor.

80. Remove two bolts and baffle assembly (120).

81. Use Tool (C) (not shown) to remove retaining ring (122). Attach Tooling (B) and a suitable lifting device to center manifold (121). Lift center manifold (121) and ball bearing (123) from the seat. The weight of the center manifold is 50 kg (110 lb).
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    Illustration 57	g00491956

82. Remove two seal rings (125) from housing assembly (124).
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    Illustration 58	g03327115

83. Position housing assembly (124) on Tool (A). The weight of housing (124) is 93 kg (205.0 lb).
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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.

84. Attach Tooling (L) and a suitable lifting device to carrier assembly (127). Remove 21 bolts (126). Remove carrier assembly (127) from housing assembly (124). The weight of carrier assembly (127) is 30 kg (66 lb).
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    Illustration 59	g00491958

85. Use Tooling (J) to remove bearing (128) from carrier assembly (127).
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    Illustration 60	g00491959

86. Remove ring seal (129) from carrier assembly (127).
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    Illustration 61	g00491960

87. Use a hammer and a brass punch to drive spring pin (131) in planet shaft (130).
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    Illustration 62	g00491961

88. Remove planetary shaft (130) from the carrier assembly. Remove spring pin (131) from planetary shaft (130).

89. Remove planetary gears (134) and (138). Remove bearings (133) and (137) from the planetary gears. Remove thrust discs (132), (135), (136), and (139) from the carrier assembly.

90. Follow Steps 87 through 89 for the remaining five gears.
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    Illustration 63	g03327774

91. Remove two clutch plates and three friction discs (141).

92. Remove seal ring (142) from gear assembly (140). Remove the six bolts under housing assembly (124) that are not shown in order to remove gear assembly (140).
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    Illustration 64	g00491963

93. Use Tool (C) (not shown) to remove retaining ring (143). Install three 3/8 inch - 16 NC forcing screws in balance piston (145). Tighten the forcing screws evenly. Remove the balance piston and ball bearing (144) as an assembly.

94. Remove ball bearing (144) and seal extension ring (146) from balance piston (145).
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    Illustration 65	g00491964

95. Remove seal ring (147) from gear assembly (140).
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    Illustration 66	g00491965

96. Remove 12 retainer springs (148) from clutch piston (149).

97. Install two 5/8 inch - 18 NC eyebolts to the clutch piston. Attach a suitable lifting device to the forged eyebolts. Attach the lifting device to a hoist. Remove clutch piston (149) from housing assembly (124).
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    Illustration 67	g00491966

98. Remove seal extension ring (150) from clutch piston (149).
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    Illustration 68	g00491967

99. Remove seal ring (153) from the housing assembly.

100. Use Tool (C) (not shown) to remove retaining ring (151). Remove shaft assembly (152) from housing assembly (124).
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     Illustration 69	g00491968

101. Carrier (155) will be destroyed when removal occurs. If carrier (155) will be removed, use a hammer and a chisel in order to break carrier (155). Remove carrier (155) and dowel (154).