980G Wheel Loader Power Train Caterpillar

Disassembly Procedure

Start By:

1. Separate the transmission from the torque converter. Refer to Disassembly and Assembly, "Transmission from Torque Converter - Separate" for the machine that is being serviced.

2. Remove the transmission hydraulic control valve. Refer to Disassembly and Assembly, "Transmission Hydraulic Control Valve - Remove" for the machine that is being serviced.

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

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Illustration 1	g01088174

1. Attach Tooling (B) and a suitable lifting device to planetary group (1). The weight of planetary group (1) is approximately 565 kg (1250 lb). Remove planetary group (1) from transmission case (2).

2. Place planetary group (1) on wood blocks.

   Note: Put alignment marks across the clutch housings for assembly purposes.

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   Illustration 2	g00833679

3. Remove bolts (3) and the washers.
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   Illustration 3	g01087353

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   Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

4. Use Tooling (D) to secure the clutch piston in No. 6 clutch housing (5).

5. Install Tooling (B) and a suitable lifting device on No. 6 clutch housing (5). The weight of No. 6 clutch housing (5) is approximately 32 kg (70 lb).

6. Carefully remove No. 6 clutch housing (5) from manifold assembly. Remove springs (4).
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   Illustration 4	g01088048

7. Remove clutch piston (6) from No. 6 clutch housing (5). Remove seals (6A) from the piston.
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   Illustration 5	g01087359

8. Remove friction discs (7), clutch plates (8), and dowels (9) from manifold assembly.
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   Illustration 6	g00833667

9. Remove gear (10) from the carrier assembly.
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   Illustration 7	g00833660

10. Use Tooling (E) to remove retaining ring (11) from shaft assembly. Remove the spacer under the retaining ring.

11. Remove carrier assembly (12).
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    Illustration 8	g01087364

12. Use a drift to bend locks (13) from bolts (14). Remove bolts (14), locks (13), and slinger (15) from carrier assembly.
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    Illustration 9	g01087372

13. Remove spring pin (16) from the carrier and shaft (17). Remove spring pin (16) from shaft (17).
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    Illustration 10	g00833652

14. Remove thrust discs (18) and (22) and gear (20).

15. Remove bearings (19) and (21) from gear (20).

16. Repeat Steps 13 through 15 for the removal of the remaining planetary gears.
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    Illustration 11	g00833623

17. Use Tooling (F) to remove retaining ring (23) from the housing assembly.

18. Remove gear (24).

19. Remove O-ring seal (25) from the manifold assembly.
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    Illustration 12	g00833618

20. Remove bolts (26) that hold the manifold assembly to the No. 4 clutch housing.
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    Illustration 13	g01088014

21. Attach Tooling (B) and a suitable lifting device to manifold assembly (27). The weight of manifold assembly (27) is approximately 72 kg (160 lb).

22. Carefully remove manifold assembly (27) from the No. 3 and the No. 4 clutch housing. Remove seals (27A).
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    Illustration 14	g00833611

23. Remove spiral ring (28) and bearing (29) from the manifold assembly.
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    Illustration 15	g00833608

24. Remove bolts (30) from the No. 4 clutch housing.
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    Illustration 16	g01088089

25. Use Tooling (D) to hold the piston in the No. 4 clutch housing (31). Attach Tooling (B) and a suitable lifting device to the No. 4 clutch housing (31). The weight of No. 4 clutch housing (31) is approximately 25 kg (55 lb).

26. Carefully remove No. 4 clutch housing (31).

27. Remove springs (32).
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    Illustration 17	g00833604

28. Remove clutch piston (33) from the No. 4 clutch housing.
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    Illustration 18	g00833601

29. Remove seals (34) and (35) from the clutch piston.
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    Illustration 19	g01084546

30. Remove friction discs (37), clutch plate (36) and dowels (38).
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    Illustration 20	g01088207

31. Remove retaining ring (39) from the shaft assembly.

32. Attach Tooling (B) and a suitable lifting device to No. 5 clutch housing (40). The weight of No. 5 clutch housing (40) is approximately 45 kg (100 lb).

33. Carefully remove No. 5 clutch housing (40).
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    Illustration 21	g00833575

34. Remove seal rings (41) from the ring carrier (42).

35. Check the condition of the ring carrier (42). If ring carrier (42) is worn or damaged, use new parts for replacement. If the ring carrier is not worn or damaged, DO NOT remove ring carrier (42). Use a hammer and a chisel in order to break the ring carrier. Remove the ring carrier and pin (43) from housing assembly.
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    Illustration 22	g01087377

36. Remove bolts (44) from the housing.

37. Remove ring gear (45) and gear (45A).
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    Illustration 23	g01089934

38. Remove friction discs (46) and four clutch plates (46A) from the housing assembly.
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    Illustration 24	g00833521

39. Remove reaction plate (47) from housing assembly (48).
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    Illustration 25	g01087191

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    Personal injury can result from being struck by parts propelled by a released spring force. Make sure to wear all necessary protective equipment. Follow the recommended procedure and use all recommended tooling to release the spring force.

40. Use Tooling (H) and a suitable press in order to put force on plate (49) until spiral lockring (50) can be removed. Release the force. Remove the plate and three springs (51) from the housing.
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    Illustration 26	g00833516

41. Remove piston (52) from the housing assembly.
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    Illustration 27	g00833510

42. Remove seals (53) and (54) from the piston.
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    Illustration 28	g01088082

43. Use Tooling (D) to hold the piston in No. 3 clutch housing (55). Attach Tooling (B) and a suitable lifting device to No. 3 clutch housing (55). The weight of No. 3 clutch housing (55) is approximately 39 kg (85 lb). Remove No. 3 clutch housing (55).

44. Remove springs (56).
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    Illustration 29	g01089975

45. Remove piston (57) from housing assembly.
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    Illustration 30	g00833462

46. Remove seals (58) and (59) from the piston.
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    Illustration 31	g01087384

47. Remove friction discs (60) and clutch plates (61).
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    Illustration 32	g01088079

48. Use Tooling (E) in order to remove retaining ring (62) from the shaft assembly.

49. Attach Tooling (B) and a suitable lifting device to carrier (63). The weight of carrier (63) is approximately 26 kg (58 lb).
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    Illustration 33	g01087392

50. Use Tooling (E) to remove retaining ring (64) from hub (65). Remove hub (65) from the carrier.
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    Illustration 34	g00833329

51. Place the carrier on suitable blocks, as shown. Use a screwdriver to compress the retainer ring. Remove gear (66) from the carrier. Remove the retainer ring.
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    Illustration 35	g00833324

52. Remove spiral lockring (67). Remove bearing (68) from the carrier.
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    Illustration 36	g00833322

53. Remove spring pin (69) from the carrier.
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    Illustration 37	g01087221

54. Remove shaft (74), thrust discs (70) and (73), and gear (71). Remove bearing (72) from the gear (71). Remove pin (69) from shaft (74).

55. Repeat Steps 53 through 54 for the removal of the remaining gears.
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    Illustration 38	g01087225

56. Remove gear (75) from the shaft assembly.
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    Illustration 39	g01087229

57. Remove bolts (76) from No. 2 clutch housing (77).

58. Use Tooling (D) to hold the piston in No. 2 clutch housing (77). Attach Tooling (B) and a suitable lifting device to No. 2 clutch housing (77). The weight of No. 2 clutch housing (77) is approximately 44 kg (97 lb).

59. Remove No. 2 clutch housing (77), springs (78), and dowels (79).
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    Illustration 40	g00833069

60. Remove clutch piston (80) from the No. 2 clutch housing.
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    Illustration 41	g00833067

61. Remove seals (81) and (82) from the clutch piston.
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    Illustration 42	g00833034

62. Remove friction discs (83) and clutch plates (84).
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    Illustration 43	g01087234

63. Remove gear (85) and plate assembly (86) from the clutch housing.
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    Illustration 44	g00833028

64. Remove friction plates (87) and clutch plates (88).
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    Illustration 45	g01088263

65. Attach Tooling (C) and a suitable lifting device to output shaft assembly (89). The weight of output shaft assembly (89) and the carrier is approximately 90 kg (200 lb).

66. Remove the retaining ring that holds output shaft assembly (89) in the bearing on the bottom of the clutch housing.

67. Remove output shaft assembly (89) and the carrier from the No. 1 clutch housing.

68. Place output shaft assembly (89) on suitable blocks.
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    Illustration 46	g00832999

69. Use Tooling (E) to remove retaining ring (90).
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    Illustration 47	g00832997

70. Use a soft hammer to remove shaft assembly (91) from the bearing in the carrier.
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    Illustration 48	g00832809

71. Remove carrier assembly (92) from the shaft assembly.
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    Illustration 49	g01087257

72. Remove seals (96) and (95) from the carrier assembly.

73. Remove spiral lockring (93).

74. Use Tooling (G) to remove bearing (94).
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    Illustration 50	g01087258

75. Use a hammer and a punch to push spring pin (97) from the carrier assembly.
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    Illustration 51	g01087259

76. Remove shaft (102), thrust discs (98) and (101), and gear (99). Remove bearing (100) from gear (99). Remove pin (97) from shaft (102).

77. Repeat Steps 75 and 76 for the remaining gears.
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    Illustration 52	g00832704

78. Remove spacer (103) and gear (104) from the shaft assembly.
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    Illustration 53	g00832696

79. Put the shaft assembly on suitable blocks, as shown. Use two people to remove carrier assembly (105) from the shaft assembly. The weight of carrier assembly (105) is approximately 32 kg (70 lb).
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    Illustration 54	g01089992

80. Put the carrier assembly on a wood block, as shown. Use a screwdriver to compress the retainer ring. Remove gear (106) from the carrier assembly. Remove retaining ring (106A).
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    Illustration 55	g01090001

81. Remove spiral lockring (107). Use Tooling (G) to remove bearing (108) from the carrier. Remove seal rings (108A).
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    Illustration 56	g00832691

82. Use a hammer and a punch to push spring pin (109) from the carrier assembly.
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    Illustration 57	g01087333

83. Remove shaft (118), thrust discs (110), (113), (114) and (117), and gears (112) and (116). Remove bearings (111) and (115) from the gears. Remove pin (109) from shaft (118).

84. Repeat Steps 82 and 83 for the remaining gears.
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    Illustration 58	g01087342

85. Remove gear (119) from the shaft assembly.

86. Remove seals (120) and (121) from the seal carrier.
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    Illustration 59	g00832673

87. Remove spiral lockring (122) from the shaft assembly.
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    Illustration 60	g00832651

88. Put shaft assembly on suitable blocks, as shown. Use a soft hammer to strike the shaft assembly (124) until the bearing is removed from the shaft assembly (123).
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    Illustration 61	g00832640

89. Remove retaining ring (125) from the shaft assembly. Remove bearing (126).
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    Illustration 62	g00832629

90. Use Tooling (H) and a suitable press to remove seal carrier (127) from the shaft assembly.
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    Illustration 63	g01088299

91. Use Tooling (L) to remove bearing (128) from the shaft assembly.
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    Illustration 64	g00832561

92. Remove gear (129) from the clutch housing.
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    Illustration 65	g00832558

93. Remove piston (130) from the No. 7 clutch housing.
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    Illustration 66	g00832555

94. Remove seals (131) and (132) from the piston.
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    Illustration 67	g00832553

95. Remove spiral lockring (133). Use Tooling (G) to remove bearing (134) from the housing.