793C Off-Highway Truck/Tractor Power Train Caterpillar

Transmission and Transfer Gears - Remove

Usage:

793C 4AR

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	6V-3145	Load Lever with (2724 kg (6000 lb) capacity)	1
B	162-8718	Torque Wrench (200 - 600 lb ft capacity)	1
B	6V-4170	Adapter	1
C	6V-0006	Governor Pliers	1

Start By:

Install the truck body retaining cable. Refer to Disassembly and Assembly, "Truck Body Retaining Cable - Remove and Install".
Remove the drive shaft guard (rear). Refer to Disassembly and Assembly, "Drive Shaft Guard - Remove and Install".

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication, NENG2500, "Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Cat products. Dispose of all fluids according to local regulations and mandates.

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At operating temperature, the oil in the power train is hot and under pressure. Hot oil can cause burns. Remove the breather filter cap when the engine is stopped and the breather cap is cool enough to touch by hand.

Slowly loosen the breather filter cap in order to release any pressure in the oil tank. Be careful of hot hydraulic oil when any lines are disconnected from the components of the power train.

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The space between the body and the frame becomes a zero clearance area when the body is lowered. Failure to install the retaining cable can result in injury or death to personnel working in this area.

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NOTICE

Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life.

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Illustration 1	g00512774

Approximately 120 L (31.7 US gal) of oil must be collected during the removal of the transmission and transfer gears. Remove plug (1) and O-ring seal (2) . Remove plug (3) and O-ring seal (4) . After the transmission and transfer gears are drained, replace plug assemblies (1) and (3) .

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Illustration 2	g00512781

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Illustration 3	g00512782

Use a suitable hoist to support main drive shaft (7) .

Remove four bolts (5) .
Note: Use a suitable pry bar to compress drive shaft (7) . Separate the drive shaft yoke from the yoke of the transfer gears as far as possible.

Remove four bolts (8) and spider (6) .

Use a suitable bar to compress drive shaft (7) to the minimum length.

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Illustration 4	g00512783

Remove two bolts (10) , two washers, guard (9) , two grommets (11) , and two spacers (12) .

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Illustration 5	g00512785

Remove bolt (15) , the washer, and clip (14) .

Remove lockwire (16) .

Use Tool (C) (not shown) in order to disconnect harness (13) from the transmission output speed sensor of the EPTC II.

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Illustration 6	g00512786

Remove two bolts (17) , two washers, and clip (20) from guard (18) .

Disconnect three transmission solenoids (19) .

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Illustration 7	g00512787

Note: Before disassembly, mark all the harnesses and the hose assemblies for installation purposes.

Remove remaining two bolts (17) , two washers, clip (20) , and guard (18) .

Remove bolt (31) and clip (20) .

Disconnect harness connector (33) . Reposition the harness for the removal of the transmission and transfer gears.

Disconnect hose assembly (23) . Remove O-ring seal (24) . If necessary, remove elbow (21) and O-ring seal (22) .

Repeat Step 15 for remaining hose assembly (25) .

Disconnect hose assembly (29) . Remove O-ring seal (30) . If necessary, remove four bolts (26) , block assembly (27) , and O-ring seal (28) .

Repeat Step 17 for remaining hose assembly (32) .

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Illustration 8	g00512788

Remove four bolts (35) , four washers, and split flange (36) . Disconnect hose assembly (34) . Remove O-ring seal (37) .

If necessary, remove two bolts (39) , bolt (41) , three washers, magnetic screen assembly (38) , and two O-ring seals (40) .

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Illustration 9	g00512791

Remove four bolts (43) , four washers, and split flange (44) . Disconnect hose assembly (42) . Remove O-ring seal (45) .

Disconnect harness connector (46) for transmission oil temperature sensor (47) .

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Illustration 10	g00512792

Use Tool (A) to support the weight of transmission and transfer gears (48) . The transmission and transfer gears weigh approximately 1960 kg (4321.1 lb).