980G Wheel Loader Power Train Caterpillar

Disassembly Procedure

Start By:

1. Separate the output transfer gears from the transmission planetary group. Refer to Disassembly and Assembly, "Output Transfer Gears from Transmission, Torque Converter - Separate" for the machine that is being serviced.

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Illustration 1	g00506763

1. Remove bolt (1) and retainer (2) from the input side of the output transfer gear case.
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   Illustration 2	g00506765

2. Remove O-ring seal (3).
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   Illustration 3	g00506766

3. Remove yoke (4).
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   Illustration 4	g00506768

4. Remove bolts (5) and the washers from bearing cage (6).
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   Illustration 5	g01088820

5. Use Tooling (D) in order to remove bearing cage (6).
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   Illustration 6	g01088826

6. Use Tooling (A) to remove lip seal (7) and outer bearing race (8) from bearing cage (6).
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   Illustration 7	g01088829

7. Remove O-ring seal (9) from bearing cage (6).
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   Illustration 8	g01088830

8. Remove spacer (10) from transfer shaft (11).
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   Illustration 9	g01088841

9. Position the transfer case (15) with the output side upward, as shown. The weight of the output transfer gear group is approximately 525 kg (1160 lb).

10. Mark bolts (12) for installation purposes. Remove bolts (12) and washers (13) from bearing cage (14).
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    Illustration 10	g01088843

11. Use Tooling (D) to loosen bearing cage (14) from the transfer case.

12. Attach a suitable lifting device around yoke assembly (16). The weight of bearing cage (14) and yoke assembly (16) as a unit is approximately 107 kg (236 lb). Carefully remove bearing cage (14) and yoke assembly (16) as a unit from the transfer case.
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    Illustration 11	g00506780

13. Remove bolt (17) and retainer (18).
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    Illustration 12	g00506781

14. Remove O-ring seal (19).

15. Remove yoke assembly (16) from transfer shaft (12).
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    Illustration 13	g00506783

16. Place bearing cage (14) in a suitable press, as shown. Press transfer shaft (12) out of bearing cage (14). The weight of transfer shaft (12) is approximately 27 kg (60 lb).

    Note: Place a suitable block under transfer shaft (12) in order to prevent transfer shaft (12) from falling to the ground during the pressing.

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    Illustration 14	g00506784

17. Use two people to remove bearing cage (14) from output gear (20). The weight of bearing cage (14) is approximately 33 kg (73 lb).
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    Illustration 15	g00506785

18. Remove spacer (21) from output gear (20).
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    Illustration 16	g00506786

19. Use Tooling (B) to push out transfer shaft (12) from bearing (22).
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    Illustration 17	g00506788

20. Remove O-ring seal (25), bolts (23), the washers and retainer (24) from bearing cage (14).
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    Illustration 18	g00506790

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    Illustration 19	g00506791

21. Use Tooling (A) and a suitable press to remove bearing cones (26) and bearing cups (27) from bearing cage (14).

22. Remove lip seal (28) from bearing cage (14).
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    Illustration 20	g00506792

23. Mark bolts (29) for installation purposes. Remove bolts (29) and the washers.

24. Remove cover (30) with O-ring seal (31).
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    Illustration 21	g00506793

25. Mark the position of input bearing cage (32) for installation purposes. Remove bolts (33), the washers and input bearing cage (32).
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    Illustration 22	g00506794

26. Remove shim pack (34).
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    Illustration 23	g00506795

27. Use Tooling (A) to remove bearing cup (35) from input bearing cage (32).
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    Illustration 24	g00506796

28. Remove nuts (36), the washers, and cover (37).
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    Illustration 25	g00506797

29. Remove O-ring seal (38).

30. Mark the position of idler bearing cage (39) for installation purposes. Remove bolts (40) and the washers.
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    Illustration 26	g00506798

31. Use bolts (40) that were removed in the previous step as forcing screws to remove idler bearing cage (39).
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    Illustration 27	g00506799

32. Remove shim pack (41).
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    Illustration 28	g00506801

33. Use Tooling (A) to remove bearing cup (42) from idler bearing cage (39).

34. Remove O-ring seal (43).
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    Illustration 29	g00506802

35. Remove bolts (44) and the washers from cover (45).
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    Illustration 30	g01088864

36. Install bolts (44) and the washers in cover (45), as shown.

37. Use Tooling (D) to remove dowel (46) from cover (45).

38. Remove two bolts (44) and the washers.

39. Repeat Steps 36 through 38 on the opposite end of the transfer case.
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    Illustration 31	g01022847

40. Install Tooling (C) and a suitable lifting device to cover (45), as shown. The weight of cover (45) is approximately 44 kg (97 lb).

41. Carefully remove cover (45) from the transfer case.
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    Illustration 32	g01088867

42. Remove idler gear (47) from the transfer case. The weight of idler gear (47) is approximately 41 kg (90 lb).

43. Remove input gear (48) and speed sensor assembly (49) from the transfer case. The weight of input gear (48) is approximately 34 kg (75 lb).
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    Illustration 33	g01088875

44. Remove two bearing cones (50) from idler gear (47).
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    Illustration 34	g01088877

45. Remove two roller bearing cones (51) from input gear (48).
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    Illustration 35	g01088878

46. Remove bearing cup (52) and roller bearing cup (53) from the transfer case.