797 Off-Highway Truck Power Train Caterpillar

Removal Procedure

Start By:

1. Remove the axle shafts. Refer to Disassembly and Assembly, "Axle Shaft - Remove".

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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 implement hydraulic oil tank is hot and under pressure. Hot oil can cause burns. To prevent possible injury, release the pressure in the implement hydraulic system before hydraulic lines or components are disconnected or removed.

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Illustration 1	g00574047

Note: Cleanliness is an important factor. Before the removal procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent contaminants from entering the system.

1. Place a suitable container under the rear axle housing assembly. Remove plug (1) and the O-ring seal from the differential and bevel gear.

2. Drain the fluid from the rear axle housing assembly. The approximate capacity of the rear axle housing assembly at the differential and bevel gear is 946 L (250 US gal).

3. Check all the O-ring seals and the components for wear or damage. Replace the components, if necessary.

4. Lubricate the O-ring seals lightly with the lubricant that is being sealed.

5. Install plug (1) and the O-ring seal to the differential and bevel gear.
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   Illustration 2	g00574049

6. Disconnect harness assembly (2).
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   Illustration 3	g00574050

7. Remove bolts (3) in order to position guard (4) out of the way.
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   Illustration 4	g00687988

8. Remove bolts (5) that secure differential and bevel gear (6) to the rear axle housing assembly.

9. Remove five bolts, screen cover (7) and the screen assembly from differential and bevel gear (6).
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   Illustration 5	g00684920

10. Position Tooling (A) onto a suitable lift truck, as shown.
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    Illustration 6	g00574053

11. Position Tooling (A) to the differential and bevel gear, as shown.

12. Install Tooling (A) to the differential and bevel gear, as shown.
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    Illustration 7	g00574060

13. Install bolts (5), as shown.

14. Use bolts (5) in order to separate differential and bevel gear (6) from the rear axle housing assembly.
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    Illustration 8	g00685049

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    Illustration 9	g00685058

15. Use Tooling (A) in order to remove differential and bevel gear (6) and the O-ring seal from the rear axle housing assembly. The weight of differential and bevel gear (6) is approximately 3356 kg (7400 lb).
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    Illustration 10	g00685131

16. Inspect all tubes and the tube assemblies for cracking and excessive wear.
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    Illustration 11	g00687994

17. Remove two covers (8) and the magnets from each side of the rear axle housing assembly.

    Note: Always inspect the magnets and clean the magnets when the differential and bevel gear is removed.