797B Off-Highway Truck Power Train Caterpillar

Disassembly Procedure

Start By:

1. Remove the torque converter housing. Refer to Disassembly and Assembly , "Torque Converter Housing - Remove".

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Illustration 1	g01004800

1. Install Tooling (A) to cover (1). Attach a suitable lifting device to Tooling (A). Secure the lifting device to a hoist.

2. Position the torque converter on a suitable stand. The weight of torque converter is 2427 kg (5350 lb).
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   Illustration 2	g00537695

3. Remove bolt (2) and plate (3). Remove yoke (4) from output shaft (5).
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   Illustration 3	g00537726

4. Attach a suitable lifting strap around yoke (4). Remove yoke (4) from output shaft (5).
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   Illustration 4	g00537732

5. Remove eight bolts (6) and the hard washers that hold relief valve (7) to cover (1). Remove relief valve (7) from cover (1).
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   Illustration 5	g00537733

6. Remove O-ring seal (8) from relief valve (7).
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   Illustration 6	g00537737

7. Remove eight bolts (9) and the hard washers that hold relief valve (10) to cover (1). Remove relief valve (10) from cover (1).
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   Illustration 7	g00537738

8. Remove O-ring seal (11) from relief valve (10).
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   Illustration 8	g00774890

9. Remove four bolts (12) and the washers that hold filler tube (13) to cover (1). Remove filler tube (13) and the O-ring seal from cover (1).
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   Illustration 9	g00785076

10. Remove strainer (14) from filler tube (13). Remove gasket (15), plate (16), and ball (17) from cap (18). Remove retaining ring (19) from cover (20) and remove cap (18). Remove dowel (21) from cover (20). Remove lever (22).
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    Illustration 10	g00774892

11. Remove electrical connectors from clip (25). Remove bypass switch (24) from cover (23).
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    Illustration 11	g00783227

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    Illustration 12	g00537747

12. Remove O-ring (26) from bypass switch (24). Remove piston (27) and spring (28) from cover assembly (23).
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    Illustration 13	g00783226

13. Disconnect the electrical connector from clip (25) and remove temperature sensor (29) and the O-ring from cover assembly (23).
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    Illustration 14	g00783229

14. Remove O-ring plugs (30) and (31) the O-ring seals from cover assembly (23).
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    Illustration 15	g00783257

15. Remove bolt (32) and clip (25). Remove six bolts (33) that hold cover assembly (23) to cover (1). Remove cover assembly (23) from cover (1).
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    Illustration 16	g00774905

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    Illustration 17	g00783266

16. Remove O-ring seal (34) and two O-ring seals (35) from cover assembly (23). Remove two screws (37) from cover assembly (23) and remove washer (36).
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    Illustration 18	g00784874

17. Remove tube assembly (38) from screen assembly (39).
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    Illustration 19	g00784877

18. Remove two screen assembly (39) from cover (1).
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    Illustration 20	g00538019

19. Loosen clamps (42) that hold hose (43) to tube assembly (40). Remove four bolts (41) that hold tube assembly (40) to transmission control and scavenge gear pump (44). Remove tube assembly (40) and two clamps (42) from transmission control and scavenge gear pump (44).
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    Illustration 21	g00538020

20. Remove rectangular seal (45) from tube assembly (40).
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    Illustration 22	g00538024

21. Loosen clamps (46) that hold hose (43) to tube assembly (47). Remove hose (41) and two clamps (46) from tube assembly (47).
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    Illustration 23	g00538030

22. Remove four bolts (48) that hold tube assembly (47) to baffle tube assembly (49). Remove tube assembly (47) from baffle tube assembly (49).
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    Illustration 24	g00538032

23. Remove rectangular seal (50) from tube assembly (47).
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    Illustration 25	g00538036

24. Remove six bolts (51) that hold baffle tube assembly (49) to cover (1). Remove baffle tube assembly (49) from cover (1).
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    Illustration 26	g00538039

25. Remove O-ring seal (52) from baffle tube assembly (49).
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    Illustration 27	g00538048

26. Loosen two clamps (54) that hold hose (55) to tube assembly (53).

27. Remove four bolts (56) that hold tube assembly (53) to transmission control and scavenge gear pump (44). Remove tube assembly (53) and two clamps (54) from transmission control and scavenge gear pump (44).
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    Illustration 28	g00538051

28. Remove O-ring seal (57) from tube assembly (53).
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    Illustration 29	g00538066

29. Loosen two clamps (58) that hold hose (55) to tube assembly (59). Remove hose (55) and two clamps (58) from tube assembly (59).
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    Illustration 30	g00538069

30. Remove four bolts (60) that hold tube assembly (59) to cover (1). Remove tube assembly (59) from cover (1).
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    Illustration 31	g00538071

31. Remove O-ring seal (61) from tube assembly (59).
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    Illustration 32	g00538162

32. Loosen two clamps (62) that hold hose (65) to tube assembly (63).

33. Remove four bolts (64) that hold tube assembly (63) to torque converter charging and transmission gear pump (66). Remove tube assembly (63) and two clamps (62) from torque converter charging and transmission gear pump (66).
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    Illustration 33	g00538170

34. Remove O-ring seal (67) from tube assembly (63).
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    Illustration 34	g00538163

35. Loosen two clamps (67) that hold hose (65) to tube assembly (68). Remove hose (65) and two clamps (67) from tube assembly (68).
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    Illustration 35	g00538169

36. Remove four bolts (70) that hold tube assembly (69) to cover (1). Remove tube assembly (69) from cover (1).
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    Illustration 36	g00538179

37. Remove O-ring seal (71) from tube assembly (69).
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    Illustration 37	g00785007

38. Remove plug (72) and the O-ring seal from the port below tube assembly (69).
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    Illustration 38	g00783371

39. Loosen two clamps (75) that hold hose (76) to tube assembly (74).

40. Remove four bolts (73) that hold tube assembly (74) to torque converter charging and transmission gear pump (66). Remove tube assembly (74) and two clamps (75) from torque converter charging and transmission gear pump (66).
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    Illustration 39	g00538191

41. Remove O-ring seal (77) from tube assembly (74).
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    Illustration 40	g00783276

42. Loosen two clamps (78) that hold hose (76) to tube assembly (79). Remove hose (76) and two clamps (78) from tube assembly (79).
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    Illustration 41	g00783278

43. Remove four bolts (80) that hold tube assembly (79) to cover (1). Remove tube assembly (79) from cover (1).
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    Illustration 42	g00538219

44. Remove O-ring seal (81) from tube assembly (79).
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    Illustration 43	g00783316

45. Remove four bolts (82) that hold manifold (83) to filter housing (84). Remove manifold (83) from filter housing (84).
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    Illustration 44	g00538224

46. Remove O-ring seal (85) from manifold (83).
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    Illustration 45	g00783317

47. Remove bolt (86) and the washer from manifold (88). Remove sleeve (87) from manifold (88).
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    Illustration 46	g00783388

48. Remove two O-ring seals (89) from sleeve (87).
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    Illustration 47	g00784883

49. Remove four bolts (90) that hold manifold (88) to torque converter charging and transmission gear pump (66). Remove manifold (89) from torque converter charging and transmission gear pump (66).
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    Illustration 48	g00538231

50. Remove O-ring seal (91) from manifold (88).
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    Illustration 49	g00538232

51. Remove four bolts (92) that hold manifold (93) to cover (1). Remove manifold (93) from cover (1).
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    Illustration 50	g00538233

52. Remove O-ring seal (94) from manifold (93).
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    Illustration 51	g01004818

53. Install Tooling (B) into the transmission control and scavenge gear pump (44). Attach a suitable lifting device to Tooling (B). Secure the lifting device to a suitable hoist.

54. Remove three bolts (95) that hold the transmission control and scavenge gear pump (44) to cover (1).

55. Remove the transmission control and scavenge gear pump (44) and the two O-ring seals from cover (1). Remove Tooling (B) from the transmission control and scavenge gear pump (44).
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    Illustration 52	g01004821

56. Install Tooling (B) and Tooling (C) into the torque converter charging and transmission gear pump (66). Attach a suitable lifting device to Tooling (B) and Tooling (C). Secure the lifting device to a suitable hoist.

57. Remove three bolts (96) that hold the torque converter charging and transmission gear pump (66) to cover (1).

58. Remove the torque converter charging and transmission gear pump (66). Remove the two O-ring seals from cover (1). Remove Tooling (B) and Tooling (C) from the torque converter charging and transmission gear pump (66).
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    Illustration 53	g00783441

59. Position a suitable lifting strap around filter housing (84). Secure the lifting strap to a suitable hoist.

60. Remove four bolts (97) that hold filter housing (84) to cover (1).

61. Remove filter housing (84) and the O-ring seal from cover (1).
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    Illustration 54	g00774930

62. Remove plug (98) and the O-ring seal from cover (1). Remove plug (99) and the O-ring seal from drain assembly (100). Remove two bolts (101) that hold drain assembly (100) to cover (1). Remove drain assembly (100) and the O-ring seal from cover (1).
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    Illustration 55	g00774937

63. Remove plug (102) and the O-ring seal from drain assembly (103). Remove two bolts (104) that hold drain assembly (103) to the housing. Remove drain assembly (103) and the O-ring seal from the housing.
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    Illustration 56	g00783515

64. Remove two bolts (105) and the washers that hold modulating valve (106) onto manifold (107). Remove modulating valve (106) from manifold (107).
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    Illustration 57	g00538646

65. Remove O-ring seal (108) from modulating valve (106).
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    Illustration 58	g00784916

66. Remove two plugs (111), and (112) and the O-ring seal from manifold (107). Remove two bolts (109) and the washers that hold manifold (107) and clip (110) to cover (1). Remove manifold (107) and clip (110) from cover (1).
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    Illustration 59	g00538781

67. Remove two O-ring seals (113) from manifold (107).
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    Illustration 60	g00538785

68. Remove O-ring plugs (114) and the O-ring seals from cover (1).
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    Illustration 61	g00538823

69. Remove speed sensor (115) and the O-ring seal from torque converter (116).
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    Illustration 62	g00538830

70. Remove 12 bolts (117) that hold torque converter (116) to cover (1).
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    Illustration 63	g00538883

71. Remove 72 bolts (118) that hold cover (1) to housing assembly (119).
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    Illustration 64	g01004833

72. Position Tooling (A) and Tooling (B) to cover (1). Attach a suitable lifting device to Tooling (A) and Tooling (B). Secure the lifting device to a hoist.

73. Remove cover (1) from housing assembly (119).
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    Illustration 65	g00784922

74. Use three bolts (118) around the edge of cover (1) in order to drive cover (1) from housing assembly (119).
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    Illustration 66	g00538935

75. Position cover (1) on a suitable stand, which is not shown.

76. Remove O-ring plugs (120) and the O-ring seals from cover (1).
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    Illustration 67	g00539003

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    Illustration 68	g00539012

77. Remove retaining rings (121) that hold oil pump gears (122) to bearings (123).

78. Remove oil pump gears (122) from bearings (123).
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    Illustration 69	g00539016

79. Remove seal (124) from oil pump gears (122).
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    Illustration 70	g00539022

80. Remove retaining rings (125) that hold bearings (123) to cover (1).
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    Illustration 71	g00784936

81. Use Tooling (D) to drive bearings (123) from cover (1).
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    Illustration 72	g00783876

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    Illustration 73	g00783877

82. Remove plug (126) and the O-ring from cover (1).
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    Illustration 74	g00783905

83. Remove six bolts (127) that hold plate (128) to cover (1). Remove plate (128) from cover (1).
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    Illustration 75	g00783906

84. Remove two plugs (129) and the O-rings from cover (1).

85. Attach a suitable lifting device to Tooling (A). Secure the lifting device to a hoist.

86. Remove cover (1) from the stand. Position cover (1) out of the way.
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    Illustration 76	g00539123

87. Remove O-ring seals (130) and (131) from torque converter (116).
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    Illustration 77	g00539240

88. Position Tooling (E) on torque converter (116). Attach a suitable lifting device to Tooling (E). Secure the lifting device to a hoist.

89. Remove torque converter (116) from housing assembly (119).
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    Illustration 78	g00784945

90. Remove two bolts (132) and the washers from torque converter (116). Use two bolts (132) and the washers to install Tooling (F) to torque converter (116).
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    Illustration 79	g00784946

91. Attach a suitable lifting device to Tooling (F). Secure the lifting device to a suitable hoist.
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    Illustration 80	g00785325

92. Rotate torque converter (116) by 180 degrees. Remove O-ring seal (133) from torque converter (116).
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    Illustration 81	g00784949

93. Position torque converter (116) in a suitable stand. Remove two bolts (132) that hold Tooling (F) to torque converter (116). Install two bolts (132) and the washers into torque converter (116). Remove Tooling (E) from torque converter (116).

    Note: Properly dispose of any excess oil that is left in housing assembly (119).

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    Illustration 82	g00785018

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    Illustration 83	g00785020

94. Remove two sleeves (134) and (135) from housing assembly (119).
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    Illustration 84	g00538505

95. Remove O-rings (136) from sleeve (135). Remove O-rings (137) from sleeve (134).
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    Illustration 85	g00784978

    Note: Properly dispose of any excess oil that is left in housing assembly (119).

96. Position a suitable lifting device into housing assembly (119). Secure the lifting device to a hoist.
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    Illustration 86	g00785387

97. Raise housing assembly (119) on the stand to a vertical position.
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    Illustration 87	g00785021

98. Remove four bolts (138) that hold plate (139) to housing assembly (119). Remove plate (139) and the O-ring from housing assembly (119).
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    Illustration 88	g00785013

99. Remove three bolts (141) from guard (140). Remove guard (140) from housing assembly (119).
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    Illustration 89	g00785012

100. Remove bolt (144) that holds clip (143) to housing assembly (119). Remove liquid level switch (142) and the O-ring from housing assembly (119).
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     Illustration 90	g00785011

101. Remove two plugs (145) and (146). Remove the O-ring seals from housing assembly (119).
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     Illustration 91	g00785024

102. Remove four bolts (147) from housing assembly (119). Remove plate (148) and the O-ring seal from housing assembly (119).
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     Illustration 92	g00774978

103. Remove two dowels (151) from housing assembly (119).

104. Remove four bolts (150) and the washers that hold support assembly (149) to the housing assembly (119). Remove support assembly (149) from the housing assembly (119).
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     Illustration 93	g00785484

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     Illustration 94	g00785482

105. Remove eight bolts (152), the nuts and the hard washers that hold support assembly (149) to flap (153). Remove flap (153) from support assembly (149).
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     Illustration 95	g00783872

106. Remove eight bolts (154) and the washers that hold cover (155) to housing assembly (119). Remove cover (154) and the gasket from housing assembly (119).
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     Illustration 96	g00785508

107. Remove two grommets (156) and (157) from housing assembly (116).
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     Illustration 97	g00784985

108. Remove plate (158) from the edge of grommet (156). Remove glass (159) from the inside of grommet (156). This disassembly was of the upper sight gauge. Perform the same procedure on lower grommet (157).
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     Illustration 98	g00785527

109. Remove six bolts (160), the nuts, and the washers from cover (161). Remove cover (161) from housing assembly (119).
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     Illustration 99	g00543357

110. Attach a suitable lifting device to housing assembly (119). Secure the lifting device to a hoist.

111. Remove torque converter housing assembly (119) from the stand. Set housing assembly (119) to the side.