797 Off-Highway Truck Power Train Caterpillar

Removal Procedure

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Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin.

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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.

Note: The axle shaft can be removed without removing the final drive sun gears.

Note: The following procedure illustrates the removal of the right axle shaft. The same removal procedure is used for the left axle shaft. The length of the right axle shaft is approximately 4585.7 mm (15.0 ft) and the weight of the right axle shaft is approximately 311 kg (686 lb). The length of the left axle shaft is approximately 3768.7 mm (12.4 ft) and the weight of the left axle shaft is approximately 256 kg (564 lb). The rear tire and the rim have been removed for the following procedure. It is not necessary to remove the rear tire and the rim to perform this procedure.

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Illustration 1	g00739534

1. Make sure that the drain plug for the final drive is in the appropriate position, as shown. Install suitable wheel chocks.

2. Place a suitable container under the final drive.

3. Remove plug (1) from the final drive. Drain the fluid from the final drive. Refer to Operation and Maintenance Manual, "Differential and Final Drive Oil and Screens - Change/Clean" for the approximate fluid capacity of the final drive.

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

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

6. Install plug (1) to the final drive.
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   Illustration 2	g00738256

7. Remove bolts (2) to remove cover (3) and O-ring seal (4) (not shown) from the rear axle housing.
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   Illustration 3	g01882399

8. Install Tooling (A) to cover (6), as shown. Attach Tooling (A) to a suitable lifting device.

9. Remove bolts (5) that secure cover (6) to the final drive.

10. Remove cover (6) and the O-ring seal from the final drive. The weight of cover (6) is approximately 120 kg (265 lb).

11. Remove the thrust washer that is located between cover (6) and the front of the final drive (not shown).
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    Illustration 4	g01882402

12. Remove plate (7) and spring (8) that is on the back of cover (6).
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    Illustration 5	g01882404

13. Install Tooling (B) to the final drive. Tooling (B) prevents the sun gear from falling when the axle shaft is removed. Thread threaded rod (X) of Tooling (B) until threaded rod (X) is in firm contact with the sun gear.
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    Illustration 6	g00826140

    Note: Tooling (C) should be used with the 145-8008 Axle Shaft and the 145-8009 Axle Shaft.Tooling (D) should be used with the 185-8902 Axle Shaft and the 185-8903 Axle Shaft.

14. Install Tooling (C) or Tooling (D) to axle shaft (9). Refer to Tool Operating Manual, M0091691 for more information on Tooling (D).
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    Illustration 7	g00826088

15. Use Tooling (C) or Tooling (D) to pull axle shaft (9) from the final drive to attach a suitable lifting device. Refer to Tool Operating Manual, M0091691 for more information on Tooling (D).
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    Illustration 8	g00826086

16. Use a suitable prybar to support the end of axle shaft (9) during the removal procedure.
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    Illustration 9	g06285173

17. Use the suitable lifting device to remove axle shaft (9). The weight of axle shaft (9) is approximately 311 kg (686 lb).

    Note: Move the suitable lifting device toward the center of axle shaft (9) to reposition weight during removal.

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    Illustration 10	g00826070

18. Disengage axle shaft (9) from the following four engagement points:

    • primary sun gear (13)

    • bearing guide (12)

    • TCS gear (11)

    • side gear (10)

    Note: These four engagement points can be damaged as axle shaft (9) is removed.

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    Illustration 11	g00826073

19. Use a small flat head screwdriver to rotate TCS gear (11) at the location that is indicated by the arrow. This will help to disengage the splines of axle shaft (9) with the splines of TCS gear (11).