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735 Articulated Truck Power Train Caterpillar


Pump Drive - Disassemble - The No. 1 Rotating Clutch is included.

Usage:

735 AWR

Disassembly Procedure

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Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1P-1861     Retaining Ring Pliers     1    
B     1P-1863     Retaining Ring Pliers     1    
C         M-12 Guide Bolts     3    
D     138-7573     Link Bracket     3    
E     6V-5230     Bolt     2    
F     8B-7551     Bearing Puller Gp     1    
G     1P-0510     Driver Gp     1    

Start By:

  1. Remove the torque converter outlet relief valve. Refer to Disassembly and Assembly, "Relief Valve (Torque Converter Outlet) - Remove and Install" for the removal procedures.
  2. Remove the torque converter housing. Refer to Disassembly and Assembly, "Torque Converter Housing - Remove".
  3. Remove the 193-0421 Speed Sensor. Refer to Disassembly and Assembly, "Speed Sensor (Transmission) - Remove and Install" for the removal procedures.
  4. Remove the transmission oil temperature sensor. Refer to Disassembly and Assembly, "Temperature Sensor (Transmission Oil) - Remove and Install" for the removal procedures.
  5. Remove the bypass valve. Refer to Disassembly and Assembly, "Bypass Valve - Remove and Install" for the removal procedures.
  6. Remove the transmission oil filter. Refer to Disassembly and Assembly, "Transmission Oil Filter - Remove and Install" for the removal procedures.

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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, "Caterpillar Tools and Shop Products Guide" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

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NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.

  1. Perform the following procedure in order to separate the No. 1 rotating clutch and the plate from the torque converter:

    Note: The No. 1 rotating clutch and the plate will be removed as a unit.

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      Illustration 1g00804495

    1. Remove eight bolts (1) and two allen head screws (2). This will allow the No. 1 rotating clutch and the plate to be removed.
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      Illustration 2g00804508

    1. Remove No. 1 rotating clutch (4) and plate (3) from the center shaft of the torque converter. The weight of the No. 1 rotating clutch and the plate is 30 kg (70 lb).

  1. Perform the following procedure in order to disassemble the No. 1 rotating clutch and the plate:
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      Illustration 3g00804514

      Typical Example

    1. Remove retaining ring (5) .
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      Illustration 4g00804515

      Typical Example

    1. Remove plate (6) and hub (7) from the inside diameter of hub (8) .
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      Illustration 5g00804517

      Typical Example

    1. Remove five friction discs (9) and five steel plates (10) .
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      Illustration 6g00804519

      Typical Example

    1. Remove the following components from the inside bore of the hub: race (13), disc (12) and race (11).
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      Illustration 7g00804529

      Typical Example

    1. Use Tool (A) to remove retaining ring (14) from the inner diameter of hub (15) .

    1. Invert the plate and the No. 1 rotating clutch in order to finish the disassembly procedure.
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      Illustration 8g00804546

    1. Use Tool (B) in order to remove retaining ring (16) from hub (15). Remove retaining ring (17) from the bearing.
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      Illustration 9g00804636

    1. Separate the following components: bearing (19), O-ring (18), plate (20) and hub (15) .

    1. Remove six bolts (21) in order to separate plate (22) from the hub.
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      Illustration 10g00804640

    1. Compress plate (24) and the disc spring in order to remove retaining ring (23). Use Tool (B) to remove the retaining ring.
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      Illustration 11g00804651

    1. Remove plate (24) .
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      Illustration 12g00804654

    1. Remove five disc springs (25) from the hub.
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      Illustration 13g00804657

    1. Remove piston (26) from the hub.
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      Illustration 14g00804665

    1. Remove inner seal (27) and outer seal (28) from the piston.
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    Illustration 15g00804667

  1. Remove eight allen head screws (29) and the washers from the torque converter housing.
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    Illustration 16g01011730

  1. Remove four bolts (31) from torque converter housing (30) in order to release the separator plate.

  1. Install Tooling (D) to the torque converter housing. Install Tooling (C) into the carrier assembly.

  1. Use Tooling (D) and a suitable hoist to raise the torque converter housing approximately 5 mm (0.1969 inch) from the torque converter. The weight of the torque converter housing is 159 kg (350 lb).
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    Illustration 17g00780796

    Insert the soft drift in hole (Z) .

  1. Use a hammer and a suitable soft drift in order to tap the separator from the torque converter housing. This will allow the torque converter housing to be separated from the torque converter.
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    Illustration 18g00804697

  1. Remove bolts (32) .
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    Illustration 19g00804701

  1. Install Tooling (E) in order to remove pump adapter (33) and O-ring (34) (not shown).

    Note: Note the orientation of pump adapter (33) for installation purposes.

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    Illustration 20g00804710

  1. Remove shim pack (35) from the torque converter housing.

    Note: Measure the shim pack thickness and record the measurement for later installation.

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    Illustration 21g00804711

  1. Place the pump adapter on suitable wood blocks. Use a hammer and a soft drift in order to remove bearing cup (36) from pump adapter (33) .
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    Illustration 22g00804722

  1. Remove pump drive gear (37) from the torque converter housing.
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    Illustration 23g00804727

  1. Remove seal (38) from the groove of the pump drive gear.
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    Illustration 24g00804732

  1. Use Tool (F) and Tool (G) in order to remove bearing cone (39) from pump drive gear (37) .
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    Illustration 25g00804737

  1. Repeat step 14 in order to remove bearing cone (40) .
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    Illustration 26g00804744

  1. Use a suitable heel bar in order to remove bearing cup (41) from the torque converter housing.

  1. Perform Step 8 through Step 16 in order to disassemble the other pump drive.

  1. Invert the torque converter housing.
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    Illustration 27g00804745

  1. Remove gear pump (42) and tube (43) from the torque converter housing. Refer to Disassembly and Assembly, "Transmission Oil and Scavenge Pump - Remove" for the removal procedure.
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    Illustration 28g00804748

  1. Remove bolt (44) .
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    Illustration 29g00804751

  1. Remove idler shaft (46) from the center of roller bearing (45). Then remove the upper half of the roller bearing from idler gear (47) .
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    Illustration 30g00804753

  1. Remove spacer (48) from the lower half of roller bearing (49) .
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    Illustration 31g00804758

  1. Remove idler gear (47) and the lower half of roller bearing (49) from the torque converter housing.
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    Illustration 32g00804760

  1. Use a hammer and a soft drift in order to remove bearing cup (50) from idler gear (47) .
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    Illustration 33g00804762

  1. Use Tool (A) to remove the two retaining rings (51) that are used as spacers from the idler gear.
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    Illustration 34g00804763

  1. Use a hammer and a soft drift in order to remove bearing cup (52) from the idler gear.

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