| Required Tools | |||
| Tool | Part Number | Part Description | Qty |
| A | 128-4773 | Lift Bracket Extension | 1 |
| A | 128-4775 | Lift Bracket Extension | 1 |
Start By:
- Install the truck body retaining cable. Refer to Disassembly and Assembly, "Truck Body Retaining Cable - Remove and Install".
- Remove the axle shafts. Refer to Disassembly and Assembly, "Axle Shafts - Remove".
- Remove the transmission and the transfer gears. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Remove".
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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, PERJ1017, "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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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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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. |
- Drain the oil from the differential into a suitable container. The differential contains approximately
663 L (175.1 US gal) of oil. - Remove two bolts (1), two washers, cover (2), and shim pack (3).
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Illustration 2 g00511963 - Use a 3/8 inch - NC bolt to remove thrust pin (4) from the differential housing. Remove O-ring seal (5) from thrust pin (4).
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Illustration 3 g00511989 Show/hide table
Illustration 4 g00511994 - Disconnect oil temperature sensor (11) of the differential.
- Remove four bolts (12), four washers, and split flange (13). Disconnect hose assembly (6). Remove O-ring seal (7). Remove sensor (14), the block assembly, and O-ring seal (15).
- Disconnect hose assembly (16). Remove O-ring seal (17). Remove elbow (18) and O-ring seal (19).
- Remove two bolts (20) and the two washers.
Note: Bolts (20) are located behind hose assemblies (6) and (16).
Note: Leave two bolts (9) in place to retain differential and bevel gear (8) until Tool (A) is in place. The differential and bevel gear must be supported to avoid personal injury or death.
Show/hide tablePersonal 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.
- Remove 26 bolts (9), 26 washers, and 26 spacers (10). Leave two bolts (9) in place until Tool (A) is supporting the differential and bevel gear.
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Illustration 5 g00511992 - Use three M20 bolts to attach Tool (A). Use Tool (A) and a suitable hoist to support differential and bevel gear (8). The weight of the differential and bevel gear is
1185 kg (2612.5 lb) .Note: A manufactured tool is shown in the place of Tool (A).
- Remove remaining two bolts (9), two washers, and two spacers (10).
- Remove differential and bevel gear (8) from the housing.
- Place the differential and bevel gear on a suitable fixture. Remove Tool (A).
- Remove O-ring seal (21) (not shown).
- Cover the opening in the housing while the differential and bevel gear is removed. This will prevent the housing from any contamination.
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| Illustration 1 | g00511959 |
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Keep all parts clean from contaminants. Contaminants may cause rapid wear and shortened component life. |
