793C Off-Highway Truck/Tractor Power Train Caterpillar

Transmission Planetary - Disassemble

Usage:

793C 4AR

Disassembly Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	138-7575	Link Bracket	2
B	8B-7554	Bearing Cup Puller	1
C	1P-2420	Repair Stand for Transmission	1
D	138-7574	Link Bracket	2
E	1P-1855	Retaining Ring Pliers	1
F	138-7573	Link Bracket	2
J	1U-8758	Retaining Ring Pliers	1
K	1P-1863	Retaining Ring Pliers	1
M	1P-0520	Driver Group	1
N	2P-8312	Retaining Ring Pliers	1
P	138-7578	Link Bracket	1

Start By:

Remove the transmission and transfer gears. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Remove" for the correct procedure.

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Illustration 1	g00512851

Use a suitable hoist to position the transmission and transfer gears on a suitable stand. The transmission and transfer gears weighs approximately 1960 kg (4321.1 lb).
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Illustration 2 g00512854
Remove four bolts (1), four washers, and step (2).
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Illustration 3 g00512855
Remove ten nuts (3) and cover (4).
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Illustration 4 g00512856
Remove gasket (5) from cover (6).
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Illustration 5 g00512857
Mark the location of three clips (7) for installation purposes. Remove three bolts (8), three clips (7), and the three washers. Remove 21 bolts (9) and cover (6) from the transmission case.
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Illustration 6 g00512860
Remove gasket (10) from the transmission case.
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Illustration 7 g00512862
Remove four bolts (11) and the four washers. Remove the manifold from the transmission case.
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Illustration 8 g00512865

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Illustration 9 g00512866
Remove eight bolts (12) and the eight washers. Remove two covers (13) and two flanges (15) with the sleeves from the transmission case.
Remove sleeve (14) from flange (15). Repeat this procedure on the remaining sleeve.
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Illustration 10 g00512887
Remove O-ring seal (16) from flange (15). Remove two O-ring seals (17) from sleeve (14). Repeat this procedure on the remaining flange and the remaining sleeve.
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Illustration 11 g00512890
For installation purposes, mark all the bolts before removal. Remove four bolts (18) and the four washers from the transmission.
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Illustration 12 g00512891
Remove bolt (19) and the washer. Use bolt (19) and the washer to install Tool (A). Use Tool (A) and a suitable lifting device to remove transmission control valve (20) from the transmission. Transmission control valve (20) weighs 68 kg (149.9 lb).
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Illustration 13 g00512892
Remove bolt (21) and retainer (22) from yoke (23).
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Illustration 14 g00512893
Remove O-ring seal (24) and yoke (23) from the transfer gear.
Note: If the transmission output speed sensor of the EPTC II is already removed, skip Steps 15 through 19.
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Illustration 15 g00512894
Remove five bolts (25), five washers, and five grommets (26). Remove sensor housing (27) and spacer (28) from the transfer gear case.
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Illustration 16 g00512895
Mark the location of retainer (29) for installation purposes. Remove four bolts (30) and the four washers. Remove retainer (29) with ring (31) from sensor housing (27).
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Illustration 17 g00512896
Use a small screwdriver to remove retaining ring (32) from ring (31).
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Illustration 18 g00512897
Use Tool (B) to remove ball bearing (33) and retainer (29) from ring (31).
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Illustration 19 g00512899
Remove drive shaft (34) from the transfer case end.
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Illustration 20 g00512900
Use Tool (D) and a suitable hoist to position the transmission and transfer gears on Tool (C). Position wood blocks under the transfer gears. Remove two of the bolts and two of the washers that hold the transmission case to the transfer gear case. Use the bolts to secure the transmission case to Tool (C).
Note: If the magnetic screen for transmission oil has already been removed, skip Steps 21 through 27.
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Illustration 21 g00512901
Remove bolt (35), the washer, and two bolts (36) from the transmission case. Remove screen housing (37) from the transmission case.
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Illustration 22 g00512903
Remove two O-ring seal (38) from screen housing (37).
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Illustration 23 g00512905
Remove eight nuts (39) and two covers (40) from screen housing (37).
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Illustration 24 g00512906
Remove two wave washers (41) and two seals (42) from screen housing (37).
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Illustration 25 g00512907
Remove two suction screens (43) and two screen tube assemblies (44) from screen housing (37). If necessary, remove studs (45) from screen housing (37).
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Illustration 26 g00512908
Remove screen tube assembly (44) from suction screen (43). Repeat this procedure on the remaining screen tube assembly.
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Illustration 27 g00512909
Remove four magnets (46) from screen tube assembly (44). Repeat this procedure on the remaining screen tube assembly.
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Illustration 28 g00512911
Loosen 17 bolts (47) until the threads of the bolts are free from the housing.

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Personal injury or death can occur from heavy components falling during removal or installation.
Properly support the component with a suitable lifting device during removal or installation.

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Illustration 29 g00512912
Remove 18 bolts (48) and the 18 washers that hold the transmission case to the transfer gear case.
Note: The two bolts that hold the transmission case and the transfer gear case to Tool (C) are included in 18 bolts (48) that must be removed. Be careful during the removal of the transmission case from the transfer gear case. Only the weight of the transmission and the transfer gear case is keeping the transmission and transfer gear case on Tool (C). Lift the transmission case enough to install the two bolts and the nuts that hold the transfer gear case to Tool (C).
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Illustration 30 g00512914
Use two bolts (49) and two nuts (49) to secure the transfer gear case to Tool (C). Lift transmission case (50) off the transfer gear case. Transmission case weighs approximately 227 kg (500.5 lb).
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Illustration 31 g00512916
Mark the sides of the carriers for easier assembly purposes. Remove O-ring seal (51) from flange (52) of the transfer gear case.
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Illustration 32 g00512917
Remove four bolts (54). Use two 3/8 inch NC forcing screws in drive adapter (53). Remove drive adapter (53).
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Illustration 33 g00512918
Use Tool (E) to remove retaining ring (55). Remove ball bearing (56).
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Illustration 34 g00512919
Remove 24 bolts (57) and 24 washers. Remove baffle (58) from the end housing.
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Illustration 35 g00512921
Remove ten bolts (59) and ten washers. Remove ring (60) and oil slinger (61) from planetary carrier (62).
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Illustration 36 g00512924
Remove O-ring seal (63) from planetary carrier (62).
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Illustration 37 g01018347
Use Tool (F) and a suitable lifting device to remove two bolts (65). Remove end housing (64). End housing (64) weighs 34 kg (74.9 lb).
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Illustration 38 g00512928
If necessary, remove two balls (66) from end housing (64).
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Illustration 39 g00512930
Remove six springs (67), six pins (68), and six springs (69). Remove six dowels (70) from clutch housing (71).
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Illustration 40 g00512931
Remove seven friction discs (72) and six clutch plates (73) from clutch housing (71).
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Illustration 41 g01013842
Use Tool (F) and a suitable lifting device to remove planetary carrier (74). Planetary carrier (74) weighs 86 kg (189.6 lb).
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Illustration 42 g00512936
Use a hammer and a punch to insert spring pin (75) in governor control shaft (76). Repeat this procedure for the four remaining assemblies.
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Illustration 43 g00512937
Remove governor control shaft (76) from planetary carrier (74). Remove two thrust discs (77), gear (78), and two roller bearings (79) from planetary carrier (74). Repeat this procedure on the four remaining assemblies.
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Illustration 44 g01018350
Use Tool (F) and a suitable lifting device to remove gear (80) from clutch housing (71). Gear (80) weighs 30 kg (66.1 lb).
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Illustration 45 g01013846
Use Tool (H) and a suitable lifting device to remove clutch housing (71). Clutch housing (71) weighs 68 kg (149.9 lb).
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Illustration 46 g00512942
Remove six long springs (81) and six short springs (82).
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Illustration 47 g01018764
Use two screwdrivers to remove clutch piston (83) from clutch housing (71).
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Illustration 48 g00512944
Remove 17 bolt dampers (84) from clutch housing (71). If necessary, remove two balls (85) and four dowels (86).
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Illustration 49 g00512945
Remove two seal rings (87) and (88) from clutch piston (83).
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Illustration 50 g00512946
Use Tool (J) to remove retaining ring (89) from ring gear (90).
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Illustration 51 g00512967
Remove five friction discs (91) and four clutch plates (92) from clutch housing (93).
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Illustration 52 g01018351
Use Tool (F) and a suitable lifting device to remove hub (94) with sun gear (95) as a unit. Hub (94) and sun gear (95) weighs 20 kg (44.1 lb).
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Illustration 53 g00512972
Remove two spring pins (96) from hub (94).
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Illustration 54 g00512974
Turn over hub (94). Use six dowels with a 1/8 inch diameter to compress the retaining ring (not shown) in hub (94). Separate hub (94) from sun gear (95). Remove the retaining ring.
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Illustration 55 g00512975
Remove spacer (97) from planetary carrier (98).
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Illustration 56 g01018354
Use Tool (F) and a suitable lifting device to remove planetary carrier (98). Planetary carrier (98) weighs 114 kg (251.3 lb).
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Illustration 57 g00512978
Use a hammer and a punch to drive spring pin (99) in shaft (100). Repeat this procedure on the four remaining shafts.
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Illustration 58 g00512979
Remove shaft (100) from planetary carrier (98). Remove two thrust discs (101), gear (102), and two roller bearings (103) from planetary carrier (98). Repeat this procedure on the four remaining shafts.
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Illustration 59 g00512981
Use Tool (K) to remove retaining ring (104) and sun gear (105) from the shaft.
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Illustration 60 g00512983
Remove eight bolts (106) and four lock plates (107) that hold ring gear (108) in position.
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Illustration 61 g01013904
Use Tool (A) and a suitable lifting device to remove clutch housing (109) and ring gear (108) as a unit. The combined weight of clutch housing (109) and ring gear (108) is 114 kg (251.3 lb).
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Illustration 62 g00512993
Remove 12 springs (110) from the transmission.
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Illustration 63 g00512995
Use two people to remove ring gear (108) from clutch housing (109). Ring gear (108) weighs 43 kg (94.8 lb).
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Illustration 64 g00512997
Use two screwdrivers to remove clutch piston (111) from clutch housing (109).
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Illustration 65 g00512998
Remove two bolt dampers (112), 17 bolt dampers (113), and two balls (114) from clutch housing (109).
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Illustration 66 g00512999
Remove two seal rings (115) and (116) from clutch piston (111).
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Illustration 67 g00513000
Remove six dowels (117) from clutch housing (118).
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Illustration 68 g00513001
Remove three friction discs (119) and two clutch plates (120) from clutch housing (118).
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Illustration 69 g00513003
Remove 16 bolts (121) and 16 washers from the transmission.
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Illustration 70 g01018362
Use Tool (A) and a suitable lifting device to remove clutch housing (118) and ring gear (122) as a unit. The combined weight of clutch housing (118) and ring gear (122) is 125 kg (275.6 lb).
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Illustration 71 g01018371
Remove ring gear (122) from clutch housing (118).
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Illustration 72 g01018373
Use two screwdrivers to remove clutch piston (123) from clutch housing (118).
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Illustration 73 g01018374
Remove four dowels (124) and two balls (125) from clutch housing (118).
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Illustration 74 g00513012
Remove seal rings (126) and (127) from clutch piston (123).
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Illustration 75 g01018501
Use Tool (F) and a suitable lifting device to remove 16 bolts (129) and 16 washers. Remove planetary carrier (128) from clutch housing (130). Planetary carrier (128) weighs 57 kg (125.7 lb).
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Illustration 76 g00513016
Use a screwdriver to remove retaining ring (131). Remove O-ring seal (132) from bearing retainer (133).
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Illustration 77 g00513018

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Illustration 78 g00513019
Turn over planetary carrier (128). Position the carrier on two wood blocks. Use Tool (M) to remove ball bearing (134) and bearing retainer (133) from planetary carrier (128).
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Illustration 79 g00513020

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Illustration 80 g00513021
Use Tool (M) and a suitable press to remove bearing retainer (133) from ball bearing (134).
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Illustration 81 g00513022
Use a hammer and a punch to insert spring pin (135) in shaft (136). Repeat this procedure on the four remaining shafts.
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Illustration 82 g00513023
Remove shaft (136) from planetary carrier (128). Remove two thrust discs (137), gear (138), and two roller bearings (139) from planetary carrier (128). Repeat this procedure on the four remaining shafts.
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Illustration 83 g00513024
Remove plug (140) from shaft (136). Repeat this procedure on the four remaining shafts.
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Illustration 84 g00513025
Remove six dowels (141) from clutch housing (130).
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Illustration 85 g00513026
Remove five friction discs (142) and four clutch plates (143) from clutch housing (130).
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Illustration 86 g01018506
Use Tool (F) and a suitable lifting device to remove sun gear (145) and hub (144) as a unit. The combined weight of sun gear (145) and hub (144) is 25 kg (55.1 lb).
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Illustration 87 g00513029

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Illustration 88 g00513032
Turn over hub (144). In order to compress retaining ring (146) in hub (144), install six dowels that have a diameter of 1/8 inch. Separate hub (144) from sun gear (145). Remove retaining ring (146) from sun gear (145).
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Illustration 89 g00513034
Remove two seal rings (147) from sun gear (145).
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Illustration 90 g00513036
Use Tool (N) to remove retaining ring (148) from the shaft.
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Illustration 91 g00513038
Use a screwdriver to remove retaining ring (149) from manifold (150).
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Illustration 92 g01013919
Use Tool (A) and a suitable lifting device to remove clutch housing (130). Clutch housing (130) weighs approximately 163 kg (359.4 lb).
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Illustration 93 g00513041

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Sudden release of spring force can cause injury.
To prevent the possibility of injury, follow the procedure to relieve the spring pressure.
Slowly loosen 9 twelve point head bolts (152) in order to release the pressure under balance piston (151). After the spring pressure has been released, remove nine bolts (152) and nine washers.
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Illustration 94 g00513044
Before the removal of clutch piston (153), mark point (V) for installation purposes. Use two screwdrivers to remove clutch piston (153) from clutch housing (130).
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Illustration 95 g00513067

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Illustration 96 g00513071
Use a screwdriver to remove retaining ring (154) from clutch housing (130). Remove two dowels (155) from clutch housing (130).
Turn over the clutch housing. Use Tool (M) to remove the ball bearing from clutch housing (130).
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Illustration 97 g00513073
Remove balance piston (151) from clutch piston (153).
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Illustration 98 g00513075
Remove seal ring (156) from balance piston (151).
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Illustration 99 g00513076
Remove 18 springs (157) from clutch piston (153).
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Illustration 100 g00513079
Remove seal ring (158) from clutch piston (153).
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Illustration 101 g00513081
Remove 16 bolts (159) and 16 washers from the transmission.
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Illustration 102 g00513082
Remove two bolts (160) and two washers that hold the tube in position on manifold (161).
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Illustration 103 g01013920
Use Tool (A) and a suitable lifting device to remove manifold (161) with the clutch as a unit. The combined weight of manifold (161) and the clutch is 125 kg (275.6 lb).
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Illustration 104 g00513086
Mark seal rings (162) and (163) for installation purposes. Remove seal ring (162) and three seal rings (163) from manifold (161).
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Illustration 105 g00513087

Use Tool (A) to turn over manifold (161). Remove Tool (A).

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Illustration 106	g00513396

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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.

Slowly loosen four remaining bolts (165) in order to release the pressure under piston (164). After the spring pressure has been released, remove four bolts (165) and four washers. Remove piston (164).
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Illustration 107 g00513397
Remove seal ring (166) from piston (164). Use a suitable press to remove bearing sleeve (167).
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Illustration 108 g00513398
Remove 18 springs (168) from clutch piston (169).
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Illustration 109 g00513402
Use two screwdrivers to remove clutch piston (169) from clutch housing (170). Remove seal ring (171) from clutch piston (169).
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Illustration 110 g00513404
Remove seal ring (172) from clutch piston (169).
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Illustration 111 g00513406
Use a screwdriver to remove retaining ring (173) from ring carrier (174).
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Illustration 112 g01013921
Remove seal ring (175) from clutch housing (170). Use Tool (F) and a suitable lifting device to remove clutch housing (170) and ball bearing (176) from ring carrier (174). Clutch housing (170) weighs 39 kg (85.9 lb).
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Illustration 113 g00513409
Turn over clutch housing (170). Remove metal seal ring (177).
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Illustration 114 g00513411

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Illustration 115 g00513413
Use Tool (M) to remove ball bearing (176) from clutch housing (170).
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Illustration 116 g00513415
Remove two seal rings (178) from ring carrier (174). Remove seven bolts (179) and seal adapter (180) from manifold (161).
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Illustration 117 g00513416
Remove seven bolts (181) that hold manifold (161) to ring carrier (174). Use two lifting slings around manifold (161) and a suitable lifting device to remove manifold (161) from ring carrier (174). Manifold (161) weighs 59 kg (130.1 lb).
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Illustration 118 g00513418
Remove two dowels (182) from ring carrier (174).
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Illustration 119 g00513419
Remove lubrication relief valve (183), two plugs (184), and the O-ring seals from manifold (161).
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Illustration 120 g00513420

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Illustration 121 g00513421

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Sudden release of spring force can cause injury.
To prevent the possibility of injury, follow the procedure to relieve the spring pressure.
Slowly loosen cap (185) until the spring pressure is released. Remove cap (185) and O-ring seal (186) from body (187) of the lubrication relief valve.
Remove spring (188), washer (189), and valve (190) from body (187) of the lubrication relief valve.
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Illustration 122 g00513423
Remove two balls (191) and two dowels (192) from manifold (161).
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Illustration 123 g00513425
Remove O-ring seal (193) from tube (194).
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Illustration 124 g00513426
Remove plug (195), four bolts (196), and the flange that holds tube (194) in place in the transfer case.
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Illustration 125 g00513427
Remove O-ring seal (197) and spring pin (198) from plug (195).
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Illustration 126 g00513428
Remove tube (194) from the bottom of the transfer case.
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Illustration 127 g00513429
Remove O-ring seal (199) from tube (194).
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Illustration 128 g01018553
Use Tool (F) and a suitable lifting device to remove housing (200). Housing (200) weighs 34 kg (74.9 lb).
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Illustration 129 g00513431
Remove six dowels (201) from the clutch housing.
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Illustration 130 g00513432
Remove five friction discs (202) and four clutch plates (203) from the clutch housing.
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Illustration 131 g00513433
Remove eight locking bolts (204), four locking plates (205), and coupling (206) from the clutch housing.
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Illustration 132 g00513434

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Illustration 133 g00513435
Install Tool (P) in shaft (207). Attach a suitable lifting device to Tool (P).
Remove shaft (207) and carrier (208) as a unit. The combined weight of shaft (207) and carrier (208) is 79 kg (174.2 lb).
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Illustration 134 g00513436
Turn over shaft (207) and carrier (208). Position shaft (207) and carrier (208) on wood blocks. Use a hammer and a punch to drive spring pin (209) into shaft (210). Repeat this procedure on the three remaining shafts.
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Illustration 135 g00513437
Remove shaft (210) from the carrier. Remove two thrust discs (211), gear (212), and two roller bearings (213) from the carrier. Repeat this procedure on the three remaining shafts.
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Illustration 136 g00513438
Remove plug (214) from shaft (210). Repeat this procedure on the three remaining shafts.
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Illustration 137 g00513439
Use a screwdriver to remove retaining ring (215) from carrier (208).
Remove carrier (208) from shaft (207). Carrier (208) weighs 23 kg (50.7 lb).
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Illustration 138 g00513440

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Illustration 139 g00513442
Remove bearing race (216) from carrier (208) in the following manner:
1. Turn over carrier (208).
2. Use a brass drift to remove bearing race (216).
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Illustration 140 g00513444
Remove sleeve bearing (217) from shaft (207).
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Illustration 141 g00513445
Remove dowel (218) from shaft (207).
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Illustration 142 g00513446
Use a pair of pliers to squeeze retaining ring (219). Remove sun gear (220).
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Illustration 143 g00513447
Use Tool (N) to remove retaining ring (219) from the center shaft.
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Illustration 144 g00513448
Use two people to remove plate (222) from clutch housing (221). Plate (222) weighs 18 kg (39.7 lb).
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Illustration 145 g00513450
Remove the two dowels from plate (222).
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Illustration 146 g00513454
Remove ring gear (223) from clutch housing (221).
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Illustration 147 g00513455
Remove ten cup plugs (224) from ring gear (223).
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Illustration 148 g00513456
Remove five friction discs (225) and four clutch plates (226) from clutch housing (221).
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Illustration 149 g01018583

Use Tool (F) and a suitable lifting device to remove clutch housing (221). Clutch housing (221) weighs 73 kg (160.9 lb).

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Illustration 150	g00513458

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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.

Slowly loosen ten bolts (228) in order to release the spring pressure that is under balance piston (227). Remove ten bolts (228), ten washers, and balance piston (227) from clutch housing (221).
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Illustration 151 g00513459
Remove 18 springs (229) from clutch piston (230).
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Illustration 152 g00513460
Use two screwdrivers to remove clutch piston (230) from clutch housing (221).
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Illustration 153 g00513462
Remove seal ring (231) from balance piston (227).
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Illustration 154 g00513464
Remove seal ring (232) from clutch piston (230).
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Illustration 155 g00513466
Mark the position of cage (233) on clutch housing (221) for assembly purposes. Position clutch housing (221) on two wood blocks. Use a brass drift to remove cage (233) from clutch housing (221).
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Illustration 156 g00513487
Remove metal seal ring (234) from cage (233). Remove six O-ring seals and roller bearing race (236) from cage (233).
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Illustration 157 g00513489
Remove seal (237) and race (238) from clutch housing (221).
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Illustration 158 g00513490
Remove two bolts (239) and the two washers. Remove tube (240) from the bearing cage.
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Illustration 159 g00513492
Remove two O-ring seals (241) from tube (240).
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Illustration 160 g00513493
Turn over transfer gear case (242). Position transfer gear case (242) on Tool (C). Transfer gear case (242) weighs 386 kg (850.9 lb).
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Illustration 161 g00513494
Remove eight bolts (243) and eight washers from transfer gear case (242).
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Illustration 162 g00513495
Use three 3/8 inch - NC forcing screws in order to remove bearing support housing (244) and center shaft (245) from transfer gear case (242).
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Illustration 163 g00513496
Use a pair of pliers to squeeze retaining ring (246). Remove bearing support housing (244) from center shaft (245).
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Illustration 164 g00513498
Use Tool (N) to remove retaining ring (246) from center shaft (245).
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Illustration 165 g00513499
Remove O-ring seals (247) and (248) from bearing support housing (244). If necessary, remove ball (249) from bearing support housing (244).
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Illustration 166 g00513500
Use a screwdriver in order to remove both retaining ring (250) and output shaft (251) from transfer gear case (242).