AD30 Underground Articulated Truck Caterpillar

Output Transfer Gears - Disassemble

Usage:

AD30 CXR

Disassembly Procedure

Show/hide table

Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	1P-0520	Driver Gp	1
B	138-7575	Link Bracket	4
C	138-7573	Link Bracket	2
D	1H-3107	Bearing Puller	1
	1H-3108	Push-Puller Leg	2
	1H-3110	Bearing Puller	1
	5F-7366	Screw	1
	5F-7351	Nut	1
	5F-7353	Washer	1
	6V-3160	Double Acting Cylinder	1
	4C-4865	Manual Hydraulic Pump	1
E	5F-7353	Washer	1
	6V-3160	Double Acting Cylinder	1
	4C-4865	Hand Hydraulic Pump	1
	1P-1839	Bearing Puller Adapter	1
	8S-6587	Adapter	1
	9S-5559	Stud	1
	1M-6756	Sleeve Assembly	1
	9H-3992	Head	1
	1P-9543	Nut	1
F	8B-7554	Bearing Cup Puller	1
	8B-7548	Bearing Puller	1
	8H-0684	Ratchet Wrench	1
G	8B-7548	Bearing Puller	1
	8B-7551	Bearing Puller	1
	9S-9154	Step Plate	1
	8H-0684	Ratchet Wrench	1
H	8B-7554	Bearing Cup Puller	1
	8B-7548	Push-Puller Tool Gp	1
	8B-7549	Puller Leg	2
	8H-0684	Ratchet Wrench	1
J	8B-7548	Push-Puller Tool Gp	1
	8B-7551	Bearing Puller	1
	5P-4170	Step Plate	1
	8H-0684	Ratchet Wrench	1

Start By:

Separate the output transfer gears. Refer to Disassembly and Assembly, "Transmission from Output Transfer Gears - Separate".

Note: Cleanliness is an important factor. Before you begin the disassembly procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism. Precision components can be damaged by contaminants or by dirt. Perform disassembly procedures on a clean work surface. Keep components covered and protected at all times.

Show/hide table

NOTICE

Failure to properly assemble parts or failure to follow established procedures can lead to damage of the parts and assembly. To avoid damage to parts, always identify and mark the parts so that they can be installed in the same location. Ensure that gear surfaces align. Never force parts during assembly.

Place the output transfer gears on suitable wood blocks.
Note: The weight of the output transfer gears is approximately 520 kg (1150 lb)
Show/hide table

Illustration 1 g01060134
Remove four bolts (2) and adapter (1).
Show/hide table

Illustration 2 g00673112
Remove O-ring seal (3).
Show/hide table

Illustration 3 g01060137
Remove bolt (4) and retainer (5).
Show/hide table

Illustration 4 g01060138
Remove O-ring seal (6) and yoke (7).
Show/hide table

Illustration 5 g01060139
Remove eight bolts (8) from bearing cage assembly (9).
Show/hide table

Illustration 6 g01060140
Use two bolts (8) as forcing screws to loosen bearing cage (9). Install the two bolts in the threaded holes. Tighten the bolts evenly until the bearing cage is loose.
Remove bearing cage assembly (9) from the transfer case.
Show/hide table

Illustration 7 g01060141
Use Tooling (A) to remove lip seal (10) from bearing cage (9).
Show/hide table

Illustration 8 g01060142
Remove the O-ring seal (11) from bearing cage (9).
Use Tooling (A) to remove the bearing cup from the bearing cage.
Show/hide table

Illustration 9 g00673137
Install Tooling (B) and a suitable lifting device to the transfer case. The weight of the transfer case is approximately 520 kg (1150 lb).
Turn the transfer case.
Place the assembly on suitable wood blocks.
Show/hide table

Illustration 10 g01060143
Remove bolt (12) and retainer (13).
Show/hide table

Illustration 11 g01060144
Remove O-ring seal (14) and yoke (15).
Show/hide table

Illustration 12 g01060476

Note: The bolts are different lengths. Identify the bolts for installation purposes.
Remove 11 bolts (16).
Show/hide table

Illustration 13 g01060482
Use two 3/8 - 16 NC forcing screws to separate bearing cage (17) from the transfer case.
Show/hide table

Illustration 14 g01060491
Install Tooling (C) and a suitable lifting device to bearing cage (17). The weight of bearing cage (17) is approximately 95 kg (210 lb).
Remove the bearing cage.
Show/hide table

Illustration 15 g01060501
Remove O-ring seal (18).
Show/hide table

Illustration 16 g00678000
Use Tooling (D) to remove the shaft assembly from the bearing cage.
Remove the gear and the spacer.
Show/hide table

Illustration 17 g01060508
Remove lip seal (19) from the bearing cage.
Show/hide table

Illustration 18 g01060510
Turn the bearing cage.
Remove six bolts (20), the washers, and retainer (21).
Show/hide table

Illustration 19 g00678004
Use Tooling (E) to remove two bearing cones (22) and one bearing cup from the bearing cage.
Show/hide table

Illustration 20 g00678049
Use Tooling (F) to remove the other bearing cup from the bearing cage.
Show/hide table

Illustration 21 g01060511
Use Tooling (G) to remove bearing (23) from the shaft.
Show/hide table

Illustration 22 g01060512
Remove nine bolts (24) and cover (25).
Show/hide table

Illustration 23 g01060513
Remove O-ring seal (26) from cover (25).
Show/hide table

Illustration 24 g01060514
Remove eight bolts (27).
Use two bolts (27) as forcing screws to loosen bearing cage (28). Install the two bolts in the threaded holes. Tighten the bolts evenly until the bearing cage is loose.
Remove bearing cage (28).
Remove the shim pack from the transfer case.
Show/hide table

Illustration 25 g00678055
Use Tooling (H) to remove the bearing cup from bearing cage (28).
Show/hide table

Illustration 26 g01060516
Remove nuts (29).
Remove cover (30).
Show/hide table

Illustration 27 g01061235
Remove seven bolts (31).
Use two bolts (31) as forcing screws to loosen bearing cage (32). Install the two bolts in the threaded holes. Tighten the bolts evenly until the bearing cage is loose.
Remove bearing cage assembly (32), O-ring seal (33), and the shim pack from the transfer case.
Show/hide table

Illustration 28 g01061238
Remove O-ring seal (34) from the bearing cage assembly.
Use Tooling (H) to remove the bearing cup from the bearing cage.
Show/hide table

Illustration 29 g01061241
Remove two bolts (35) and drain assembly (36).
Show/hide table

Illustration 30 g01061242
Remove bolts (37) that hold the gear case cover to the transfer case.
Show/hide table

Illustration 31 g01061698
Install Tooling (C) and a suitable lifting device to gear case cover (38).
The weight of the cover is approximately 45 kg (100 lb).
Remove the cover from the transfer case.
Show/hide table

Illustration 32 g01061252
Remove speed sensors (39) and (40) from the transfer case.
Show/hide table

Illustration 33 g01061257
Attach a suitable lifting device to gear (41). The weight of the gear is approximately 39 kg (86 lb).
Remove gear (41) from the transfer case.
Show/hide table

Illustration 34 g01061258
Use Tooling (J) to remove two bearing cones (42) from gear (41).
Show/hide table

Illustration 35 g01061259
Attach a suitable lifting device to gear (43). The weight of the gear is approximately 29 kg (64 lb).
Remove gear (43) from the transfer case.
Use Tooling (F) to remove bearing cups (44) and (45) from the transfer case.
Show/hide table

Illustration 36 g01061260
Remove two bearing cones (46) from gear (43).