797 Off-Highway Truck Power Train Caterpillar

Disassembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	202-2056	Shipping Stand	1
B	138-7574	Link Bracket	4
C	138-7575	Link Bracket	1
D	138-7573	Link Bracket	3
E	1P-1853	Retaining Ring Pliers	1
F	138-7576	Link Bracket	4
G	196-8520	Forcing Bolt M30 - 3.5 x 177.8 mm Long	2
H	154-6184	Forcing Bolt M20 - 2.5 x 250 mm Long	2
J	1P-1863	Retaining Ring Pliers	1
K	136-1452	Retaining Ring Pliers As	1
L	3E-3879	Eyebolt	1
M	6V-4249	Bolt	2
N	1P-2420	Transmission Repair Stand	1
	FT-0996	Positioning As	4
	Ft-0957	Positioning As	4
P	FT-3108	Plate	1
R	5F-7343	Bearing Puller Gp	1
	1P-1840	Bearing Puller Adapter	1
S	1D-4595	Bolt	3
	1D-5118	Nut	3
T	8B-7554	Bearing Cup Puller Gp	1
	7S-7786	Puller Leg	2
U	9S-9152	Bearing Puller Gp	1
V	154-6182	Forcing Bolt M12 - 1.75 x 150 mm Long	2
W	8B-7551	Bearing Puller Gp	1
	8B-7548	Push-Puller Tool Gp	1
	1P-0510	Driver Gp	1

Start By:

1. Remove the transmission.

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Illustration 1	g01419863

1. Attach a suitable lifting device to planetary transmission (1) , as shown. Position planetary transmission (1) on Tooling (A) . The weight of planetary transmission (1) is approximately 6123 kg (13500 lb).

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Illustration 2	g01419841

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Illustration 3	g01419886

2. Attach Tooling (B) and a suitable lifting device to yoke (2) . The weight of yoke (2) is approximately 45 kg (100 lb). Remove bolt (3) and plate (4) from yoke (2) . Remove O-ring seal (5) . Use Tooling (B) and the suitable lifting device in order to remove yoke (2) .

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Illustration 4	g01419893

3. Remove seal ring (6) from yoke (2) .

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Illustration 5	g01419905

4. Remove bolts (7) . Disconnect pressure sensor (8) from harness assembly (9) . Disconnect oil temperature sensor (10) from harness assembly (9) .

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Illustration 6	g01420181

5. Remove lockwire (11) .

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Illustration 7	g01420175

6. Disconnect differential switch (13) from harness assembly (9) . Disconnect solenoid connector (14) from harness assembly (9) . Remove bolts (12) and remove harness assembly (9) .

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Illustration 8	g01420214

7. Remove oil temperature sensor (10) and the O-ring seal. Remove bolts (16) and remove clips (15) . Remove pressure sensor (8) and the O-ring seal. Remove adapter assembly (17) and the O-ring seal.

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Illustration 9	g01420327

8. Remove bolts (21) in order to disconnect hose assembly (20) . Remove bolts (18) in order to remove relief valve assembly (19) .

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Illustration 10	g01420485

9. Remove O-ring seals (22) , O-ring seals (23) , and O-ring seal (24) from relief valve assembly (19) . Remove valve assembly (25) .

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Illustration 11	g01420505

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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.

10. Remove O-ring seal (30) from valve assembly (25) . Remove cap (26) . Remove spring (27) and washers (28) . Remove valve (29) .

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Illustration 12	g01420501

11. Remove sleeves (31) and sleeves (32) .

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Illustration 13	g01420532

12. Remove O-ring seals (33) from sleeves (31) .

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Illustration 14	g01420537

13. Remove O-ring seals (34) from sleeves (32) .

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Illustration 15	g01420543

14. Remove bolts (35) in order to remove manifold (36) .

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Illustration 16	g01420595

15. Remove O-ring seal (37) from manifold (36) .

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Illustration 17	g01420582

16. Remove sleeve (38) .

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Illustration 18	g01420604

17. Remove O-ring seals (39) from sleeve (38) .

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Illustration 19	g01420611

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Illustration 20	g01420638

18. Remove bolt (40) . Remove differential switch (13) , if necessary. Attach Tooling (C) and a suitable lifting device to filter assembly (42) . The weight of filter assembly (42) is approximately 68 kg (150 lb). Remove bolts (41) . Use Tooling (C) and the suitable lifting device in order to remove filter assembly (42) .

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Illustration 21	g01420652

19. Remove O-ring seal (43) from filter assembly (42) .

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Illustration 22	g01420659

20. Remove sleeve (44) .

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Illustration 23	g01420662

21. Remove O-ring seals (45) from sleeve (44) .

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Illustration 24	g01420666

22. Remove nuts (46) and remove cover (47) from housing assembly (48) .

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Illustration 25	g01420675

23. Remove O-ring seals (49) from cover (47) .

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Illustration 26	g01420678

24. Remove magnetic screen assemblies (50) and screen assemblies (51) from housing assembly (48) .

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Illustration 27	g01420694

25. Attach Tooling (D) and a suitable lifting device to housing assembly (48) . The weight of housing assembly (48) is approximately 32 kg (71 lb). Remove bolts (52) . Use Tooling (D) and the suitable lifting device in order to remove housing assembly (48) .

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Illustration 28	g01420714

26. Remove bolts (53) from cover (54) .

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Illustration 29	g01420725

27. Attach Tooling (D) and a suitable lifting device to cover (54) . Remove cover (54) and the gasket. The weight of cover (54) is approximately 45 kg (100 lb).

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Illustration 30	g01421200

28. Remove hose assemblies (55) .

    Note: Be sure to mark the location of each hose assembly (55) for assembly purposes.

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Illustration 31	g01421223

29. Disconnect harness assembly (56) . Remove bolts (57) .

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Illustration 32	g01421224

30. Remove nut (58) from solenoid connector (14) . Remove bolts (59) and the plate. Push solenoid connector (14) through the housing.

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Illustration 33	g01421240

31. Remove sleeve (60) .

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Illustration 34	g01421249

32. Remove O-ring seals (61) from sleeve (60) .

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Illustration 35	g01421254

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Illustration 36	g01421266

33. Loosen fitting (62) and fitting (64) . Disconnect fitting (62) and fitting (64) in order to remove tube assembly (63) .

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Illustration 37	g01421268

34. Remove bolts (65) .

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Illustration 38	g01421271

35. Attach a suitable lifting device to hydraulic control assembly (66) . The weight of hydraulic control assembly (66) is approximately 34 kg (75 lb). Move hydraulic control assembly (66) enough to help disengage the sleeves from the transmission. Use the suitable lifting device in order to remove hydraulic control assembly (66) .

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Illustration 39	g01421279

36. Remove bolts (67) in order to remove relief valve (68) from hydraulic control assembly (66) .

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Illustration 40	g01421285

37. Remove fittings (69) and the O-ring seals from relief valve (68) .

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Illustration 41	g01421312

38. Remove plug (70) .

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Illustration 42	g01421314

39. Remove O-ring seal (71) from plug (70) .

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Illustration 43	g01421318

40. Remove slug (72) from relief valve (68) .

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Illustration 44	g01421325

41. Remove bolts (73) and the washers in order to remove adjustment cover (74) .

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Illustration 45	g01421331

42. Remove O-ring seal (75) from adjustment cover (74) .

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Illustration 46	g01421337

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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.

43. Remove bolts (76) and the washers. Remove cover (77) from relief valve (68) .

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Illustration 47	g01421341

44. Record the length of bolt (78) for installation purposes. If necessary, remove bolt (78) from cover (77) .

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Illustration 48	g01421354

45. Remove O-ring seal (79) from relief valve (68) .

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Illustration 49	g01421360

46. Remove stop (81) and spring (80) .

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Illustration 50	g01421369

47. Remove spool (82) from relief valve (68) .

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Illustration 51	g01421376

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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.

48. Use Tooling (E) in order to remove retaining ring (83) from spool (82) .

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Illustration 52	g01421386

49. Remove retainer (86) , spring (85) , and ball (84) from spool (82) .

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Illustration 53	g01421390

50. Remove orifice plug (87) from spool (82) .

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Illustration 54	g01421392

51. Disconnect harness assembly (56) and remove harness assembly (56) from hydraulic control assembly (66) .

    Note: Be sure to mark each harness assembly connection point for assembly purposes.

52. Remove bolts (88) and remove modulating valve (89) from hydraulic control assembly (66) . Repeat this step for the remaining modulating valves (89) .

    Note: Be sure to mark each modulating valve (89) for assembly purposes.

53. Remove drains (90) from hydraulic control assembly (66) .

54. Loosen bolts (91) and remove sleeves (92) from hydraulic control assembly (66) .

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Illustration 55	g01421411

55. Remove O-ring seals (93) from sleeve (92) . Repeat this step for the remaining sleeves (92) .

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Illustration 56	g01421417

56. Remove connector (94) and the O-ring seals from modulating valve (89) .

57. Remove nut (97) , washer (96) , and coil assembly (95) from modulating valve (89) .

58. Repeat Step 56 and Step 57 for the remaining modulating valves (89) .

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Illustration 57	g01421508

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Illustration 58	g01421541

59. Attach Tooling (F) and a suitable lifting device to planetary transmission (1) in order to position planetary transmission (1) onto suitable cribbing (not shown). The weight of planetary transmission (1) is approximately 5670 kg (12500 lb). Remove bolts (98) .

60. Install Tooling (G) . Use Tooling (G) , Tooling (F) , and the suitable lifting device in order to separate the output case assembly (99) from input case assembly (100) . Position output case assembly (99) onto suitable cribbing (not shown). The weight of output case assembly (99) is approximately 3992 kg (8800 lb).

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Illustration 59	g01421536

61. Remove cap (101) and the O-ring seal. Remove bolts (103) and the washers. Remove drain assembly (102) and the O-ring seal.

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Illustration 60	g01421567

62. Remove bolts (104) .

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Illustration 61	g01421603

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Illustration 62	g01421616

63. If necessary, install Tooling (H) to output planetary (106) . Separate output planetary (106) from case (105) .

    Note: Position suitable cribbing under output planetary (106) prior to removing Tooling (H) .

64. Remove Tooling (H) . Install Tooling (B) and a suitable lifting device to output planetary (106) . Remove output planetary (106) from case (105) . The weight of output planetary (106) is approximately 2957 kg (6520 lb). Position output planetary (106) onto suitable cribbing.

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Illustration 63	g01421622

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Illustration 64	g01421733

65. Remove bolts (107) . Use three bolts (107) as forcing bolts in order to help in the removal of manifold (108) from output planetary (106) .

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Illustration 65	g01421741

66. Remove bolts (109) that hold support housing (110) to output planetary (106) .

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Illustration 66	g01421745

67. Attach Tooling (B) and a suitable lifting device to support housing (110) . Remove support housing (110) from output planetary (106) . The weight of support housing (110) is approximately 236 kg (520 lb).

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Illustration 67	g01421751

68. Remove plugs (111) and the O-ring seals from support housing (110) .

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Illustration 68	g01421754

69. Remove bolts (112) .

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Illustration 69	g01421757

70. Attach Tooling (C) and a suitable lifting device to retainer (113) . Remove retainer (113) . The weight of retainer (113) is approximately 23 kg (51 lb).

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Illustration 70	g01422050

71. Remove seal rings (114) .

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Illustration 71	g01422154

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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.

72. Remove bolts (115) .

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Illustration 72	g01422208

73. Attach Tooling (B) and a suitable lifting device to separator plate (116) . Remove separator plate (116) from output planetary (106) . The weight of separator plate (116) is approximately 77 kg (170 lb). Remove springs (117) .

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Illustration 73	g01422214

74. Remove clutch plates (118) , separator springs (119) , and friction discs (120) .

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Illustration 74	g01422251

75. Remove dowels (121) and clutch plate (122) .

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Illustration 75	g01422257

76. Install Tooling (D) and a suitable lifting device onto carrier assembly (123) . Remove carrier assembly (123) from output planetary (106) . The weight of carrier assembly (123) is approximately 195 kg (430 lb).

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Illustration 76	g01422382

77. Remove dowel (125) and remove ring carrier (124) from carrier assembly (123) .

78. Remove bolts (126) , oil slinger (127) , and the ring from carrier assembly (123) .

    Note: Discard bolts (126) .

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Illustration 77	g01422397

79. Drive spring pin (129) into shaft (128) . Remove shaft (128) from carrier assembly (123) . Remove spring pin (129) from shaft (128) . Remove gear (132) and thrust discs (130) from carrier assembly (123) . Remove bearings (131) from gear (132) . Repeat this step for the remaining planetary gears.

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Illustration 78	g01422408

80. Use suitable prybars in order to raise ring gear (133) . Position suitable cribbing under ring gear (133) . Attach a suitable lifting device onto ring gear (133) . Remove ring gear (133) from output planetary (106) . The weight of ring gear (133) is approximately 54 kg (120 lb).

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Illustration 79	g01422444

81. Attach Tooling (D) and a suitable lifting device to clutch piston (134) . Remove clutch piston (134) from output planetary (106) . The weight of clutch piston (134) is approximately 27 kg (60 lb).

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Illustration 80	g01423139

82. Remove seal ring (135) and seal ring (136) from clutch piston (134) .

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Illustration 81	g01422449

83. Attach Tooling (B) and a suitable lifting device to clutch housing (137) . Remove clutch housing (137) from output planetary (106) . The weight of clutch housing (137) is approximately 245 kg (540 lb).

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Illustration 82	g01422472

84. Remove bolt dampers (138) from clutch housing (137) .

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Illustration 83	g01422474

85. Remove retaining ring (139) and retaining ring (140) . Attach Tooling (D) and a suitable lifting device to hub assembly (141) in order to remove hub assembly (141) from output planetary (106) . The weight of hub assembly (141) is approximately 32 kg (70 lb).

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Illustration 84	g01422482

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Illustration 85	g01422504

86. Reposition Tooling (D) and the suitable lifting device onto hub assembly (141) and position hub assembly (141) onto a suitable work bench. Compress lock ring (142) (not shown). Use Tooling (D) and the suitable lifting device in order to lower hub (143) after compressing lock ring (142) (not shown). Remove lock ring (142) and remove hub (143) from hub assembly (141) .

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Illustration 86	g01422526

87. Remove bolts (144) and remove bearing cap (145) from output planetary (106) .

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Illustration 87	g01422528

88. Use Tooling (J) in order to remove retaining ring (146) . Remove bearing (147) from output planetary (106) .

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Illustration 88	g01423002

89. Attach Tooling (C) and a suitable lifting device to output shaft assembly (148) . Remove output shaft assembly (148) and carrier assembly (149) from output planetary (106) . The combined weight of output shaft assembly (148) and carrier assembly (149) is approximately 290 kg (640 lb).

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Illustration 89	g01423008

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Illustration 90	g01423013

90. Remove spring pins (150) in order to remove retaining ring (151) .

91. Use Tooling (C) and the suitable lifting device in order to separate output shaft assembly (148) from carrier assembly (149) . The weight of output shaft assembly (148) is approximately 122 kg (270 lb).

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Illustration 91	g01423028

92. Drive spring pin (153) into shaft (152) . Remove shaft (152) from carrier assembly (149) . Remove spring pin (153) from shaft (152) . Remove gear (156) and thrust discs (154) from carrier assembly (149) . Remove bearings (155) from gear (156) . Repeat this step for the remaining planetary gears.

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Illustration 92	g01423048

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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.

93. Remove bolts (157) .

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Illustration 93	g01423055

94. Attach Tooling (B) and a suitable lifting device to plate assembly (158) . Remove plate assembly (158) . The weight of plate assembly (158) is approximately 82 kg (180 lb). Remove springs (159) from output planetary (106) .

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Illustration 94	g01423071

95. Remove clutch plates (160) . Remove separator springs (161) . Remove friction discs (162) .

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Illustration 95	g01423086

96. Remove dowels (163) and clutch plate (164) from output planetary (106) .

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Illustration 96	g01423094

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Illustration 97	g01423119

97. Attach Tooling (B) and a suitable lifting device to housing assembly (167) in order to support housing assembly (167) , ring gear (165) , and clutch piston (166) . The combined weight of housing assembly (167) , ring gear (165) , and clutch piston (166) is approximately 367 kg (810 lb). Remove bolts (168) and the washers. Remove lock plates (169) . Use Tooling (B) and the suitable lifting device in order to remove housing assembly (167) , ring gear (165) , and clutch piston (166) as one unit.

    Note: Discard bolts (168) . Discard the washers, if equipped. (In any case, new washers will be installed during the assembly procedure.

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Illustration 98	g01423233

98. Attach Tooling (D) and a suitable lifting device to clutch piston (166) . Remove clutch piston (166) . The weight of clutch piston (166) is approximately 27 kg (60 lb). Use a suitable lifting device in order to remove ring gear (165) . The weight of ring gear (165) is approximately 122.5 kg (270 lb).

99. Remove bolt dampers (170) from housing (167) .

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Illustration 99	g01423371

100. Remove seal rings (171) from clutch piston (166) .

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Illustration 100	g01423379

101. Remove springs (174) and clutch plates (172) . Remove separator springs (173) and friction discs (175) .

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Illustration 101	g01423411

102. Remove clutch plate (176) and remove dowels (177) .

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Illustration 102	g01423418

103. Use two people in order to remove ring gear (179) . The weight of ring gear (179) is approximately 32 kg (70 lb). Attach Tooling (D) and a suitable lifting device to clutch piston (178) . Remove clutch piston (178) .

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Illustration 103	g01423432

104. Remove seal rings (180) from clutch piston (178) .

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Illustration 104	g01423435

105. Remove bolts (181) . Remove plugs (182) and the O-ring seals.

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Illustration 105	g01423456

106. Attach Tooling (B) and a suitable lifting device to housing assembly (183) . Remove housing assembly (183) . The weight of housing assembly (183) is approximately 132 kg (290 lb).

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Illustration 106	g01423544

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Illustration 107	g01423520

107. Position suitable cribbing under shaft (184) . Remove retaining ring (185) in order to remove sun gear (186) . Use a suitable prybar in order to remove bearing retainer (187) .

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Illustration 108	g01423561

108. Remove bolts (189) . Attach Tooling (D) and a suitable lifting device to carrier assembly (188) . Remove carrier assembly (188) . The weight of carrier assembly (188) is approximately 122 kg (270 lb).

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Illustration 109	g01423577

109. Use Tooling (K) in order to remove retaining ring (190) . Remove roller bearing (191) from carrier assembly (188) .

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Illustration 110	g01423605

110. Drive spring pin (193) into shaft (192) . Remove shaft (192) from carrier assembly (188) . Remove spring pin (193) from shaft (192) . Remove gear (196) and thrust discs (194) from carrier assembly (188) . Remove bearings (195) from gear (196) . Repeat this step for the remaining planetary gears.

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Illustration 111	g01423619

111. Remove clutch plates (197) and four friction discs (198) (not shown).

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Illustration 112	g01423628

112. Remove clutch plate (200) .

113. Attach Tooling (D) to sun gear assembly (199) . Remove sun gear assembly (199) . The weight of sun gear assembly (199) is approximately 54 kg (120 lb).

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Illustration 113	g01423652

114. Remove seal rings (201) from sun gear assembly (199) .

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Illustration 114	g01423663

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Illustration 115	g01423680

115. Position sun gear assembly (199) over suitable cribbing. Be sure that the suitable cribbing is approximately 12.7 mm (0.50 inch) below hub (203) . Compress lock ring (202) (not shown) in order to allow hub (203) to be lowered onto the suitable cribbing. Remove lock ring (202) and remove hub (203) from sun gear (203A) .

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Illustration 116	g01423696

116. Attach Tooling (L) and a suitable lifting device to shaft (184) . Remove shaft (184) . The weight of shaft (184) is approximately 100 kg (220 lb).

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Illustration 117	g01423863

117. Remove O-ring seal (204) and seal ring (205) from shaft (184) .

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Illustration 118	g01430160

118. If necessary, remove sleeve bearing (207) and remove orifice plug (206) from shaft (184) .

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Illustration 119	g01430170

119. If necessary, remove orifice setscrew (208) from shaft (184) .

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Illustration 120	g01423876

120. Remove seal ring (210) . Use a suitable punch in order to remove pin (211) . Use suitable prybars in order to remove carrier ring (209) .

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Illustration 121	g01423899

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Illustration 122	g01423903

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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.

121. Remove two bolts (212) and install Tooling (M) in order to contain balance piston (213) during the removal process.

122. Evenly remove the remaining bolts (212) .

     Note: Be careful when you remove bolts (212) . Balance piston (213) is under spring pressure. Removing bolts (212) may result in sudden movement of balance piston (213) .

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Illustration 123	g01423911

123. Install three bolts (212) into the locations for the pusher bolts. Use bolts (212) in order to help remove balance piston (213) . Remove Tooling (M) and remove balance piston (213) after all spring pressure has been released.

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Illustration 124	g01423935

124. Remove seal ring (214) from balance piston (213) .

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Illustration 125	g01423944
Your transmission may be equipped with a wave spring (215) , as shown.

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Illustration 126	g01423953
Your transmission may be equipped with coil springs (216) , as shown.

125. Remove wave spring (215) or remove springs (216) .

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Illustration 127	g01423963

126. Remove clutch piston (217) and remove dowels (218) .

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Illustration 128	g01423977

127. Remove seal ring (219) from clutch piston (217) .

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Illustration 129	g01423989

128. Remove retaining ring (221) . Attach Tooling (D) and a suitable lifting device to clutch housing (220) . Remove clutch housing (220) . The weight of clutch housing (220) is approximately 95 kg (210 lb).

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Illustration 130	g01423996

129. Remove seal ring (223) from clutch housing (220) . Remove bearing (222) from clutch housing (220) .

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Illustration 131	g01424082

130. Remove seal rings (224) . Remove bolts (225) and remove ring carrier (226) .

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Illustration 132	g01425105

131. Remove bolts (227) in order to remove sleeve manifold (228) .

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Illustration 133	g01425973

132. Attach Tooling (P) to Tooling (N) .

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Illustration 134	g01425117

133. Remove bolts (229) that hold input planetary (230) to input case assembly (100) .

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Illustration 135	g01425119

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Illustration 136	g01425120

134. Attach Tooling (B) and a suitable lifting device to input planetary (230) in order to remove input planetary (230) from case (231) . The weight of input planetary (230) is approximately 1134 kg (2500 lb). The technician will need to rotate input planetary (230) in a clockwise direction in order to complete the removal of input planetary (230) from case (231) .

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Illustration 137	g01425986

135. Position input planetary (230) onto Tooling (P) and Tooling (N) . Remove speed sensor (232) from input planetary (230) .

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Illustration 138	g01426043

136. Remove bolts (233) and remove plate (234) from input planetary (230) .

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Illustration 139	g01426055

137. Attach Tooling (B) to housing (235) . The weight of housing (235) is approximately 159 kg (350 lb). Remove bolts (236) in order to remove housing (235) from input planetary (230) .

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Illustration 140	g01426071

138. Remove carrier (237) from housing (235) .

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Illustration 141	g01426084

139. Remove seal rings (238) from carrier (237) .

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Illustration 142	g01426190

140. Reposition housing (235) . Remove retaining ring (239) and remove bearing (240) .

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Illustration 143	g01426198

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Illustration 144	g01426202

141. Remove bolts (241) . Install three bolts (241) in order to use as pusher bolts. Remove rotor (242) .

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Illustration 145	g01426229

142. Attach Tooling (D) and a suitable lifting device in order to remove carrier assembly (243) . The weight of carrier assembly (243) is approximately 91 kg (200 lb).

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Illustration 146	g01426235

143. Drive spring pin (245) into shaft (244) . Remove shaft (244) from carrier assembly (243) . Remove spring pin (245) from shaft (244) . Remove gear (248) and thrust discs (246) from carrier assembly (243) . Remove bearings (247) from gear (248) . Repeat this step for the remaining planetary gears.

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Illustration 147	g01426244

144. Remove retaining ring (249) and remove sun gear (250) .

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Illustration 148	g01426257

145. Remove bolts (251) in order to remove lock plates (252) . Use two people in order to remove ring gear (253) . The weight of ring gear (253) is approximately 32 kg (70 lb).

     Note: Discard bolts (251) .

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Illustration 149	g01426280

146. Attach Tooling (D) and a suitable lifting device to carrier assembly (254) in order to remove carrier assembly (254) . The weight of carrier assembly (254) is approximately 73 kg (160 lb).

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Illustration 150	g01426291

147. Remove retaining ring (256) in order to remove bearing carrier (255) and bearing (257) from carrier assembly (254) .

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Illustration 151	g01426304

148. Use Tooling (R) and a suitable press in order to remove bearing carrier (255) (not shown) from bearing (257) .

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Illustration 152	g01426315

149. Drive spring pin (262) into shaft (261) . Remove shaft (261) from carrier assembly (254) . Remove spring pin (262) from shaft (261) . Remove gear (260) and thrust discs (258) from carrier assembly (254) . Remove bearings (259) from gear (260) . Repeat this step for the remaining planetary gears.

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Illustration 153	g01426331

150. Remove sun gear (263) .

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Illustration 154	g01426371

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Illustration 155	g01426383

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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.

151. Attach Tooling (B) and a suitable lifting device to plate (265) . The weight of plate (265) is approximately 91 kg (200 lb). Remove bolts (264) . Raise plate (265) enough in order to remove springs (266) . Remove plate (265) .

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Illustration 156	g01426390

152. Remove clutch plates (267) and remove four friction discs (268) (not shown).

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Illustration 157	g01426399

153. Remove clutch plate (269) .

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Illustration 158	g01426403

154. Attach Tooling (D) and a suitable lifting device to ring gear (270) in order to remove ring gear (270) . The weight of ring gear (270) is approximately 45 kg (100 lb).

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Illustration 159	g01426427

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Illustration 160	g01426455

155. Remove three dowels (271) . Remove 17 bolt dampers (272) (not shown). Attach Tooling (S) in order to secure clutch plate (274) to clutch housing (273) .

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Illustration 161	g01426469

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Illustration 162	g01426471

156. Attach Tooling (C) and a suitable lifting device to clutch housing (273) . The combined weight of clutch housing (273) and clutch plate (274) is approximately 132 kg (290 lb). Raise clutch housing (273) and the clutch plate approximately 25 mm (1.0 inch). Remove springs (275) . Remove clutch housing (273) and clutch plate (274) .

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Illustration 163	g01426477

157. Remove Tooling (S) in order to remove clutch plate (274) from clutch housing (273) .

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Illustration 164	g01426496

158. Remove clutch piston (276) and clutch piston (277) (not shown) from clutch housing (273) .

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Illustration 165	g01426505

159. Remove seal ring (278) and seal ring (279) from clutch piston (276) . Repeat this step for clutch piston (277) (not shown).

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Illustration 166	g01426610

160. Remove dowels (280) , friction discs (281) , and clutch plates (282) .

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Illustration 167	g01426617

161. Attach Tooling (D) to carrier assembly (283) in order to remove carrier assembly (283) . The weight of carrier assembly (283) is approximately 91 kg (200 lb).

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Illustration 168	g01426632

162. Remove retaining ring (284) that holds bearing (285) in position to carrier assembly (283) .

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Illustration 169	g01426638

163. Attach Tooling (T) and a suitable lifting device to bearing carrier (286) . Use Tooling (T ) and the suitable lifting device in order to remove bearing (285) , bearing carrier (286) , and sun gear (287) (not shown) as one from carrier assembly (283) .

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Illustration 170	g01426677

164. Use a suitable prybar in order to remove sun gear (287) from bearing carrier (286) .

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Illustration 171	g01426680

165. Remove O-ring seal (288) from sun gear (287) .

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Illustration 172	g01426684

166. Remove seal rings (289) from bearing carrier (286) . Remove bearing (285) from bearing carrier (286) .

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Illustration 173	g01426693

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Illustration 174	g01426700

167. Position carrier assembly (283) over suitable cribbing. Be sure that the suitable cribbing is approximately 12.7 mm (0.50 inch) below hub (206) . Compress lock ring (290) (not shown) in order to allow coupling (291) to be lowered onto the suitable cribbing. Remove lock ring (290) and remove coupling (291) from carrier assembly (283) .

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Illustration 175	g01426726

168. Remove thrust buttons (292) from coupling (291) .

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Illustration 176	g01426729

169. Drive spring pin (294) into shaft (293) . Remove shaft (293) from carrier assembly (283) . Remove spring pin (294) from shaft (293) . Remove gear (297) and thrust discs (295) from carrier assembly (283) . Remove bearings (296) from gear (297) . Repeat this step for the three remaining planetary gears.

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Illustration 177	g01428764

170. Drive spring pin (298) into shaft (299) . Remove shaft (299) from carrier assembly (283) . Remove spring pin (298) from shaft (299) . Remove gear (302) and thrust discs (300) from carrier assembly (283) . Remove bearings (301) from gear (302) . Repeat this step for the three remaining planetary gears.

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Illustration 178	g01428779

171. Remove plate assembly (303) .

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Illustration 179	g01428798

172. Remove bolts (304) and remove end plate (305) .

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Illustration 180	g01428803

173. Remove clutch plates (307) and remove four friction discs (308) (not shown). Remove ring gear (306) .

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Illustration 181	g01428841

174. Remove sleeve bearing (309) from ring gear (306) .

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Illustration 182	g01428843

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Illustration 183	g01428853

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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.

175. Remove thrust disc (311) . Remove two bolts (310) and install Tooling (M) in order to contain clutch piston (313) during the removal process.

176. Evenly remove remaining bolts (312) .

     Note: Be careful when you remove bolts (312) . Clutch piston (313) is under spring pressure. Removing bolts (312) may result in sudden movement of clutch piston (313) .

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Illustration 184	g01428879

177. Install two bolts (312) into the locations for the pusher bolts. Use bolts (312) in order to release all spring pressure. Remove Tooling (M) and remove clutch piston (313) .

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Illustration 185	g01428886

178. Remove seal ring (314) from clutch piston (313) .

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Illustration 186	g01428902

179. Remove dowels (315) , springs (316) , and hub (317) . Remove clutch piston (318) .

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Illustration 187	g01428929

180. Remove seal ring (319) from clutch piston (318) .

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Illustration 188	g01428942

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Illustration 189	g01428972

181. Attach Tooling (C) and a suitable lifting device to clutch housing (320) . The weight of clutch housing (320) is approximately 50 kg (111 lb). Remove retaining ring (321) . Remove clutch housing (320) .

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Illustration 190	g01428990

182. Remove seal ring (322) from clutch housing (320) .

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Illustration 191	g01429023

183. Remove bearing (323) from clutch housing (320) .

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Illustration 192	g01429028

184. Remove bolts (325) from ring carrier assembly (324) .

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Illustration 193	g01429117

185. Install bolts (325) into the locations for the pusher bolts. Use bolts (325) in order to help remove ring carrier assembly (324) . Remove ring carrier assembly (324) .

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Illustration 194	g01429123

186. Remove seal ring (326) and seal rings (327) from ring carrier assembly (324) .

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Illustration 195	g01429159

187. Remove bolts (328) from ring carrier (329) .

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Illustration 196	g01429166

188. Use Tooling (V) in order to remove ring carrier (329) .

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Illustration 197	g01429196

189. Remove lip seal (330) from ring carrier (329) . Remove toric ring (331) from ring carrier (329) .

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Illustration 198	g01429136

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Illustration 199	g01429210

190. Attach Tooling (U) onto input shaft (332) . Attach Tooling (D) and a suitable lifting device to Tooling (U) . Use Tooling (U) , Tooling (D) and the suitable lifting device in order to support input shaft (332) . The weight of input shaft (332) is approximately 59 kg (130 lb).

191. Remove O-ring seal (333) . Use Tooling (K) in order to remove retaining ring (334) . Use Tooling (D) , Tooling (U) , and the suitable lifting device in order to lower input shaft (332) to the ground.

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Illustration 200	g01429225

192. Remove plugs (336) and the O-ring seals from clutch housing (335) . Attach Tooling (B) and a suitable lifting device in order to remove clutch housing (335) . The weight of clutch housing (335) is approximately 118 kg (260 lb).

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Illustration 201	g01429283

193. Position input shaft (332) onto suitable cribbing. Attach Tooling (W) to input shaft (332) in order to remove bearing (337) .