D400E Series II Articulated Truck Power Train Caterpillar

Disassembly Procedure

Start By:

1. Remove the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Remove".

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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.

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Illustration 1	g00586609

1. Remove six O-rings (1) from manifold (2).

   Note: Mark coils (3) for installation purposes.

2. Remove two nuts (4). Remove the two coils.

3. Remove plug (5) from the manifold. Remove the seals from the plug.
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   Illustration 2	g00586610

4. Remove cartridges (6) from the manifold.
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   Illustration 3	g00586614

5. Remove O-rings (7) and backup rings (8).
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   Illustration 4	g00586615

6. Remove two bolts (9), the cover, and wire connector (10) from the manifold.
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   Illustration 5	g00586617

7. Remove lip seal (11).
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   Illustration 6	g00586618

8. Use Tooling (A) and a hydraulic press in order to remove bearing (12) from the manifold.
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   Illustration 7	g00586621

9. Remove two plugs (13) from selector and pressure control valve (14). Remove the O-rings from the plugs.
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   Illustration 8	g00586622

   Note: The control valves for each clutch are identified by a letter on the valve body. The letters are located on the outer edge of valve body (15) in front of each valve. It is important to not mix parts between valve groups.

10. Remove two bolts (16) and the washers that secure body (17).

11. Remove two springs (18) , shims (19), and two pistons (20) from body (17).

12. Remove spring (21), orifice (22), O-ring (23), and three plugs (24).

    Note: There is no center plug on valve group (H).

13. Remove stop (25), spool (26), and spring (27).

14. Remove slug (28) from spool (26).

    Note: Repeat Steps 10 through 14 in order to disassemble each valve group.

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    Illustration 9	g00586624

    Note: Repeat Steps 15 through 16 in order to disassemble the spool from each valve group.

15. Remove retaining ring (32) from the spool.

16. Remove retainer (31), spring (30), and ball (29).
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    Illustration 10	g00586625

17. Remove bolt (33), washer (34), and piston (35).
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    Illustration 11	g00586626

18. Remove cover (36), spool (37), and spring (38).

19. Remove ring (39), retainer (40), spring (41), and check valve (42) from spool (37).

20. Remove retaining ring (43) and shims (44) from the spool.
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    Illustration 12	g00586628

21. Remove cover (45), spool (46), and spring (47).

22. Remove O-ring (48) from cover (45).
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    Illustration 13	g00586629

23. Use Tooling (B) in order to remove retaining ring (49).

24. Use a 8 - 32 threaded rod (50) in order to remove seat (51) and the O-ring. Remove ball (52) and spring (53).

25. Remove the O-ring from seat (51).
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    Illustration 14	g00586631

26. Remove two bolts (54). Remove actuator (55).
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    Illustration 15	g00586639

27. Remove two bolts (56). Remove cover (57).
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    Illustration 16	g00586640

28. Use Tooling (A) and a hydraulic press in order to remove bearing (58).
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    Illustration 17	g00586641

29. Remove rotor (59) from the actuator.
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    Illustration 18	g00586645

30. Remove two bolts (60) and vane (61).
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    Illustration 19	g00586646

31. Remove two plugs (62) from the actuator. Remove the valve and the O-ring beneath each plug.

32. Use Tooling (A) and a hydraulic press in order to remove bearing (63).
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    Illustration 20	g00586647

33. Remove two bolts (64). Remove retainers (65) and springs (66).

34. Remove bolt (67), the washer, and rotary selector spool (68).
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    Illustration 21	g00586648

35. Remove pin (69), cam (70), and screen (71) with the O-ring seal from spool (68). Remove two pins (72) from pin (69).
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    Illustration 22	g00586650

36. Remove pin (74) from spool (68). If necessary, remove dowel (75).
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    Illustration 23	g00586651

    Note: The support is under spring pressure. Apply pressure to the support as you remove the bolts.

37. Remove two bolts (76). Remove support (77). If necessary, remove the two dowels (78) from the support.
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    Illustration 24	g00586653

38. Remove spool (79) and spring (80). Remove shims (81) from the spool.
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    Illustration 25	g00586657

39. Use Tooling (B) in order to remove retaining ring (82) from spool (79).

40. Remove slug (83), spring (84), and ball (85) from the spool.
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    Illustration 26	g00586658

41. Remove cap (86), spring (87), and valve (88). Remove spacer (89) from the valve.
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    Illustration 27	g00586660

42. Remove body (90). Remove the O-ring from the body.