D250E Series II and D300E Series II Articulated Trucks Power Train Caterpillar

Transmission and Transfer Gears - Remove

Usage:

Removal Procedure

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Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	137-7575	Link Bracket	1
	6V-3114	Chain	2
	6V-3145	Load Leveler	1
B	1U-9758	Stand	1

Start By:

Remove the cab. Refer to Disassembly and Assembly, SENR9129, "Cab - Remove" .

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Personal injury can result from driveline torque windup under load.
Unequal wheel speed can result in driveline torque windup which can cause driveline components to be under load during disassembly.

Relieve the driveline torque windup before disassembly.

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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 machine. 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 in Caterpillar machines. Dispose of all fluids according to local regulations and mandates.

Note: Put identification marks on all lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.

Drain the oil from the transmission and transfer gear.

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Illustration 1	g00518545

Disconnect hydraulic hoses (1) and (6) from adapter block (2) . Remove four bolts (5) , the washers and two half clamps (3) in order to disconnect hydraulic hose (4) from adapter block (2) . Remove the O-ring seals from the hoses.

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Illustration 2	g00518605

Remove four bolts (9) , the washers and two half clamps (7) in order to disconnect hydraulic hose (8) from the transmission oil filter. Remove the O-ring seal from the hose.

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Illustration 3	g00518620

Remove four bolts (11) , the washers and two half clamps (13) in order to disconnect hydraulic hose (12) from suspension accumulator (10) . Remove four bolts (16) , the washers and two half clamps (15) in order to disconnect hydraulic hose (14) from suspension accumulator (10) . Remove the O-ring seals from the hoses.

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Illustration 4	g00518631

Disconnect electrical connectors (17) and (20) . Remove allen head screw (19) and disconnect electrical connectors (18) .

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Illustration 5	g00518632

Disconnect electrical connector (21) .

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Illustration 6	g00518635

Remove two nuts (23) , the washers and the U-bolt that secures bracket (22) to the exhaust system. Remove four bolts (25) and the washers that secure bracket (22) to crossbar (24) . Remove bracket (22) from the crossbar and the exhaust system.

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Illustration 7	g00518788

Remove bolt (29) , the washer and hose clamp (30) that secures hose bundle (26) to bracket (27) . Remove two bolts (28) and the washers that secure bracket (27) to the machine frame. Remove bracket (27) from the machine frame.

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Illustration 8	g00518637

Attach a nylon lifting strap (32) and a hoist to suspension accumulator (10) . Remove two bolts (31) , the washers and the spacers that secure suspension accumulator (10) and crossbar (24) to the mounting bracket. Use the hoist in order to remove suspension accumulator (10) from crossbar (24) . The weight of the accumulator is 45 kg (99 lb) .

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Illustration 9	g00518640

Attach a nylon lifting strap (34) and a hoist to crossbar (24) . Remove four bolts (33) , the washers and four spacers (35) that secure crossbar (24) to mounting post (39) . Remove two bolts (36) , the washers and two spacers (37) that secure crossbar (24) to mounting post (40) . Electric control module (38) will be removed with crossbar (24) . The combined weight of the components is 43 kg (95 lb) .

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Illustration 10	g00520393

Disconnect hydraulic hose (41) from lockup clutch and solenoid valve (43) . Remove electronic connector (42) from the retainer. Disconnect electronic connector (42) . Remove the O-ring seal from the hose.

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Illustration 11	g00520395

Remove four bolts (46) , the washers and two half clamps (47) in order to disconnect hydraulic hose (44) from priority valve (45) . Remove four bolts (50) , the washers and two half clamps (48) in order to disconnect hydraulic hose (51) from priority valve (45) . Disconnect hydraulic hose (49) from the mounting bracket. Remove the O-ring seals from the hoses.

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Illustration 12	g00520396

Attach a nylon lifting strap and a hoist to mounting bracket (52) . Remove two bolts (53) , the washers and the spacers that secure mounting bracket (52) to the machine frame. Use the hoist in order to remove mounting bracket (52) , lockup clutch and solenoid valve (43) and priority valve (45) as a unit from the machine frame. The combined weight of the components is 29 kg (64 lb) .

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Illustration 13	g00520417

Disconnect hydraulic hose (57) from the transmission. Disconnect fitting (58) from the transmission. Remove eight bolts (55) , the washers and four half clamps (54) in order to disconnect hydraulic hoses (59) and (60) from the transmission. Remove the O-ring seals from the hoses.

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Illustration 14	g00520418

Disconnect hydraulic hoses (61) and (62) from the transmission. Remove the O-ring seals from the hoses.

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Illustration 15	g00520419

Remove eight bolts (64) , the washers and four half clamps (63) in order to disconnect hydraulic hoses (65) and (66) from the transmission. Remove the O-ring seals from the hoses.

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Illustration 16	g00520421

Remove four bolts (67) that secure drive shaft (68) to the transmission. Move drive shaft (68) away from the transmission.

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Illustration 17	g00520424

Remove 12 bolts (71) , the washers and six half clamps (72) in order to disconnect hydraulic hoses (69) , (70) and (73) from the hoist control valve. Remove reusable hose straps (77) and (81) from the hydraulic hoses. Remove the O-ring seals from the hoses.

Disconnect hydraulic hoses (76) , (74) and (75) from the hoist control valve. Remove the O-ring seals from the hoses.

Remove bolt (79) , the nut and the washers that secure hose clamp (78) to the mounting bracket. Remove hose clamp (78) and move hydraulic hose (80) aside.

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Illustration 18	g00520426

Remove four bolts (83) , the washers and two half clamps (82) in order to disconnect hydraulic pipe (84) from the hoist control valve. Remove the O-ring seal from the hydraulic pipe.

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Illustration 19	g00520427

Disconnect electrical connectors (85) and (86) . Remove wire clamps (87) , (89) and (90) that secure wire harness (88) to the hydraulic pipe. Move wire harness (88) aside.

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Illustration 20	g00520428

Attach lifting slings (91) and a hoist to hoist control valve (92) . Remove three bolts (93) , the washers and the nuts that secure hoist control valve (92) to the transmission. The weight of hoist control valve (92) is 62 kg (137 lb) .

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Illustration 21	g00520429

Remove four bolts (95) that secure hitch drive shaft (96) to hitch assembly (94) . Move hitch drive shaft (96) away from hitch assembly (94) .

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Illustration 22	g00520430

Remove four bolts (97) that secure hitch drive shaft (96) to the transmission. Use two persons in order to remove hitch drive shaft (96) from the machine. The weight of hitch drive shaft (96) is 24 kg (53 lb) .

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Illustration 23	g00520788

Remove two bolts (98) and the washers that secure hydraulic pipe (99) to magnetic strainer (100) . Remove the O-ring seal from the hydraulic pipe.

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Illustration 24	g00520432

Attach Tooling (A) and a hoist to transmission (101) . Apply a slight upward pressure to the transmission.

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Illustration 25	g00520433

Remove six bolts (103) and six spacers (102) that secure transmission (101) to the machine frame.

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Illustration 26	g00520434

Remove two reusable wire straps (105) from the hose bundle. Remove two hose clamps (106) that secure the hoses to the machine frame. Hydraulic hose (104) will be removed with the transmission. The rest of the hoses will be moved aside for purposes of clearance.

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Illustration 27	g00520435

Remove six bolts (108) and the washers that secure the transmission to transmission mount (107) . Remove the bolts and the washers from the transmission mount that is located on the other side of the machine.

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Illustration 28	g00520441

Remove reusable wire strap (109) from mounting post (39) . Move wire assembly (110) aside for clearance.

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Illustration 29	g00520442

Remove reusable wire strap (111) from mounting post (40) . Move wire assembly (112) aside for clearance.

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Illustration 30	g00520436

Use the hoist in order to raise the transmission (101) partially out of the machine. The weight of the transmission is 1136 kg (2504 lb). Use Tooling (A) in order to tilt the transmission, as shown. Do not damage hydraulic hose (104) by maneuvering the transmission.