525C, 535C and 545C Wheel Skidders Power Train Caterpillar

Disassembly Procedure

Table 1

Required Tools
Tool	Part Number	Part Description	Qty
A	138-7573	Link Bracket	1
B	126-7175	Push-Puller Tool Gp	4
C	1P-2420	Transmission Repair Stand	1
D	2P-8312	Retaining Ring Pliers	1
F	9U-7480	Compressing Tube	1
G	1P-1863	Retaining Ring Pliers	1
H	9U-7479	Compressing Tube	1
J	1U-6341	Threaded Rod	1
K	5P-7970	Nut	1
L	154-6182	Forcing Bolt	1

Start By:

1. Separate the transmission from the torque converter. Refer to Disassembly and Assembly, "Transmission and Torque Converter - Separate".

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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 Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates.

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.

Note: Put identification marks on all sections of the transmission for assembly purposes.

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Illustration 1	g00984312

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Illustration 2	g01272038

1. Use Tooling (A) and a suitable lifting device to remove shaft assembly (1) from the transmission case and position shaft assembly (1) on Tooling (C) , as shown. The weight of shaft assembly (1) is approximately 50 kg (110 lb).

   Note: Hold input shaft (2) away from shaft (1) for clearance.

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Illustration 3	g00961189

2. Use Tooling (D) to remove retaining ring (3) and remove thrust disc (4) .

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Illustration 4	g00961435

3. Remove gear and hub assembly (5) .

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Illustration 5	g00961444

4. Use Tooling (G) to remove retaining ring (6) .

5. Separate hub (7) from hub assembly (5) . If necessary, remove sleeve bearing (8) .

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Illustration 6	g00961455

6. Remove thrust disc (9) and retainer (10) .

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Illustration 7	g00961468

7. Use Tooling (D) to remove retaining ring (11) .

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Illustration 8	g00961492

8. Use a suitable screwdriver to remove retaining ring (12) .

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Illustration 9	g00961507

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Illustration 10	g00961630

9. Remove end plate (13) , clutch plates (14) , and friction discs (15) .

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Illustration 11	g00961639

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Illustration 12	g00961647

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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.

10. Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) .

11. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) to remove retaining ring (16) . Remove Tooling (F) .

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Illustration 13	g00961656

12. Remove balance seal assembly (17) .

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Illustration 14	g00961678

13. Remove wave spring (18) .

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Illustration 15	g00974947

14. Remove piston assembly (19) .

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Illustration 16	g00974948

15. Balance seal assembly (17) . Wave spring (18) will be removed with piston (19) . Check the lips on the seals for damage or wear. Replace the seals if it is necessary.

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Illustration 17	g00974949

16. Use Tooling (A) and a suitable lifting device to reposition the shaft assembly, as shown. The weight of the shaft assembly is approximately 50 kg (110 lb).

17. Remove three seal rings (20) . Use Tooling (D) to remove retaining ring (21) .

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Illustration 18	g00974950

18. Remove thrust disc (22) .

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Illustration 19	g00974951

19. Remove washer (23) and gear (24) .

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Illustration 20	g00974953

20. Remove spacer assembly (25) .

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Illustration 21	g00974954

21. Remove thrust disc (26) , the gear, and hub assembly (27) .

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Illustration 22	g00974955

22. Use Tooling (G) to remove retaining ring (28) . Separate hub assembly (27) from gear (29) . If necessary, remove sleeve bearing (30) .

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Illustration 23	g00974956

23. Remove thrust disc (31) and retainer (32) .

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Illustration 24	g00974957

24. Use Tooling (D) to remove retaining ring (33) .

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Illustration 25	g00974958

25. Use a screwdriver to remove retaining ring (34) .

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Illustration 26	g00974959

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Illustration 27	g00974960

26. Remove end plate (35) , clutch plates (36) , and friction discs (37) .

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Illustration 28	g00974961

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Illustration 29	g00974962

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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.

27. Position the shaft assembly with the opening in retaining ring (38) in line with the opening in Tooling (F) .

28. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown).

29. Use Tooling (D) to remove retaining ring (38) and remove Tooling (F) .

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Illustration 30	g00974963

30. Remove balance seal assembly (39) .

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Illustration 31	g00974964

31. Remove wave spring (40) .

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Illustration 32	g00974965

32. Remove piston seal (41) .

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Illustration 33	g00988356

33. Remove seal rings (41A) and (41B) from piston (41) . Replace the seals, if necessary.

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Illustration 34	g00974967

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Illustration 35	g01272041

34. Use Tooling (A) and a suitable lifting device in order to remove shaft assembly (42) and position shaft assembly (42) on Tooling (C) , as shown. The weight of shaft assembly (42) is approximately 41 kg (90 lb).

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Illustration 36	g00975449

35. Use Tooling (D) to remove retaining ring (43) and remove thrust disc (44) .

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Illustration 37	g00975452

36. Remove gear and hub assembly (45) .

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Illustration 38	g00975454

37. Use Tooling (G) to remove retaining ring (46) . Separate hub assembly (45) from gear (47) . Remove sleeve bearing (48) , if necessary.

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Illustration 39	g00975456

38. Remove thrust disc (49) and retainer (50) .

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Illustration 40	g00975458

39. Use Tooling (D) to remove retaining ring (51) .

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Illustration 41	g00975463

40. Use a suitable screwdriver to remove retaining ring (52) .

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Illustration 42	g00975467

41. Remove one end plate (53) , clutch plates (54) , and friction discs (55) .

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Illustration 43	g00975553

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Illustration 44	g00975555

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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.

42. Position the shaft so the opening in retaining ring (56) will line up with the opening in Tooling (F) .

43. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) to remove the retaining ring (56) . Remove Tooling (F) .

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Illustration 45	g00975558

44. Remove balance seal assembly (57) .

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Illustration 46	g00975562

45. Remove wave spring (58) .

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Illustration 47	g00975564

46. Remove piston assembly (59) .

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Illustration 48	g00988355

47. Remove seal rings (59A) , and (59B) from piston (59) . Replace the seals if it is necessary.

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Illustration 49	g00975570

48. Use Tooling (A) (not shown) and a suitable lifting device in order to position the shaft assembly on Tooling (C) , as shown. The weight of the shaft assembly is approximately 43 kg (95 lb).

49. Remove three seal rings (60) . Use Tooling (D) to remove retaining ring (61) .

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Illustration 50	g00975576

50. Remove thrust disc (62) and gear assembly (63) .

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Illustration 51	g00975578

51. Remove sleeve bearings (64) , if necessary.

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Illustration 52	g00975579

52. Remove thrust disc (65) and retainer (66) .

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Illustration 53	g00975584

53. Use Tooling (D) to remove retaining ring (67) . Use a suitable screwdriver to remove retaining ring (68) .

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Illustration 54	g00975585

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Illustration 55	g00975587

54. Remove end plate (69) , clutch plates (70) , and friction discs (71) .

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Illustration 56	g00975588

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Illustration 57	g00975810

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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.

55. Position the shaft assembly so the opening in retaining ring (72) will be in line with the opening in Tooling (F) .

56. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (G) to remove retaining ring (72) . Remove Tooling (F) .

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Illustration 58	g00975811

57. Remove balance seal assembly (73) .

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Illustration 59	g00975812

58. Remove wave spring (74) .

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Illustration 60	g00975818

59. Remove piston seal (75) .

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Illustration 61	g00988354

60. Remove seal rings (76) and (77) from piston (75) . Replace the seals if it is necessary.

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Illustration 62	g00975828

61. Remove input shaft group (78) .

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Illustration 63	g00975867

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Illustration 64	g00976174

62. Use a suitable press to remove carrier (80) , bearing cone (81) , and gear (82) from shaft (78) .

63. Remove seal ring (79) .

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Illustration 65	g00976184

64. Reposition shaft (78) (not shown) in order to remove bearing cone (83) , and gear (84) .

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Illustration 66	g01272168

65. Disconnect harness assembly (86) and remove sensor (85) .

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Illustration 67	g00976215

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Illustration 68	g00976227

66. Use Tooling (A) and a suitable lifting device to remove shaft assembly (87) and position shaft assembly (87) on Tooling (C) , as shown. The weight of shaft assembly (87) is approximately 82 kg (180 lb).

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Illustration 69	g00976228

67. Use Tooling (D) to remove retaining ring (88) . Remove thrust disc (89) .

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Illustration 70	g00976229

68. Remove gear (90) .

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Illustration 71	g00976230

69. Use Tooling (D) to remove retaining ring (91) .

70. Separate hub assembly (92) from gear (90) . If necessary, remove sleeve bearing (93) .

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Illustration 72	g00976232

71. Remove thrust disc (94) and retainer (95) .

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Illustration 73	g00977380

72. Use Tooling (D) to remove retaining ring (96) .

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Illustration 74	g00977422

73. Use a suitable screwdriver to remove retaining ring (97) .

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Illustration 75	g00977424

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Illustration 76	g00977433

74. Remove end plate (98) , clutch plates (100) , and disc assembly (99) .

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Illustration 77	g00977426

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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.

75. Install Tooling (F) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown).

76. Use Tooling (D) to remove retaining ring (101) . Release the pressure on the wave spring and remove Tooling (F) .

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Illustration 78	g00977438

77. Remove balance seal assembly (102) .

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Illustration 79	g00977441

78. Remove wave spring (103) .

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Illustration 80	g00977444

79. Apply suitable air pressure to the passage in order to move piston (104) upward. Remove piston (104) from the shaft.

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Illustration 81	g00977446

80. Balance seal assembly (102) , wave spring (103) , and piston (104) upon removal. Check the lips on the seals for damage or wear. Replace the seals, if necessary.

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Illustration 82	g01272046

81. Use Tooling (A) and a suitable lifting device to rotate shaft assembly (78) to the opposite side on Tooling (C) . The weight of shaft assembly (78) is approximately 45 kg (100 lb).

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Illustration 83	g00977453

82. Remove seal rings (105) .

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Illustration 84	g00977455

83. Remove thrust disc (106) .

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Illustration 85	g00979038

84. Use Tooling (D) to remove retaining ring (107) .

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Illustration 86	g00979043

85. Remove gear (108) .

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Illustration 87	g00979049

86. Remove thrust disc (109) .

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Illustration 88	g00979054

87. Remove gear and hub assembly (110) .

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Illustration 89	g00979056

88. Use Tooling (G) to remove retaining ring (111) .

89. Separate hub assembly (112) from gear (110) .

90. If necessary, remove sleeve bearing (113) .

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Illustration 90	g00979059

91. Remove thrust disc (114) and ring retainer (115) .

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Illustration 91	g00979060

92. Use a suitable screwdriver to remove retaining ring (116) .

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Illustration 92	g00979063

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Illustration 93	g00979064

93. Remove end plate (117) , clutch plates (118) , and friction discs (119) .

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Illustration 94	g00979070

94. Use Tooling (G) to remove retaining ring (120) .

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Illustration 95	g00979073

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Illustration 96	g00979077

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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.

95. Position the shaft assembly so retaining ring (121) lines up with the opening on Tooling (H) .

96. Install Tooling (H) , Tooling (J) , and Tooling (K) in order to compress the wave spring (not shown). Use Tooling (D) in order to remove retaining ring (121) . Remove Tooling (H) .

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Illustration 97	g00979089

97. Remove balance piston (122) .

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Illustration 98	g00979091

98. Remove wave spring (123) .

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Illustration 99	g00979099

99. Remove piston (124) .

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Illustration 100	g00984232

100. Balance seal assembly (124) , wave spring (123) , and piston (122) upon removal. Check the lips on the seals for damage or wear. Replace the seals if it is necessary.

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Illustration 101	g00984236

101. Remove seals (124) and (126) from piston (124) .

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Illustration 102	g00984239

102. Remove thrust disc (127) from transmission case (132) .

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Illustration 103	g00984240

103. Remove bearings (128) , (129) , and (130) from transmission case (132) .

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Illustration 104	g00984243

104. Use Tooling (B) to remove bearing cone (131) from shaft (133) in transmission case (132) .

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Illustration 105	g01272211

105. Rotate the transmission case. Remove bolts (135A) and brake drum (135) . Remove the yoke and brake drum (135) .

106. Remove bolt (134) , the retainer, and yoke (134A) .

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Illustration 106	g00984245

107. Remove bolts (136) . Remove parking brake group (137) .

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Illustration 107	g00984247

108. Remove bolts (138) .

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Illustration 108	g00984248

109. Use Tooling (L) to remove bearing cage (139) .

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Illustration 109	g00984249

110. Remove shims (140) , bearing cup (141) , seal (142) , and seal (143) from bearing cage (139) .

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Illustration 110	g00984251

111. Remove shaft assembly (133) .

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Illustration 111	g00984252

112. Use a suitable press to remove bearing cone (145) and gear (144) from shaft assembly (133) .

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Illustration 112	g01272164

113. Remove bolts (147) and bearing cage (146) from transmission case (132) .

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Illustration 113	g01272199

114. Remove bearing cup (150) , seal (149) , and shims (148) from bearing cage (146) .

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Illustration 114	g00984255

115. Remove bolts (151) and remove cover (152) .

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Illustration 115	g00984256

116. Remove suction screen (153) and magnetic screen (154) .

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Illustration 116	g00960379

117. Remove bearings (156) and (157) from cover (155) .

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Illustration 117	g00960522

118. Remove the torque converter from cover (155) .

119. Remove bearing (158) , bearing cup (159) , and seal (160) from cover (155) .