735C, 740C EJECTOR and 745C Articulated Trucks Power Train Caterpillar

Disassembly Procedure

Start By:

1. Remove the torque converter.

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Illustration 1	g06247838

1. Replace all gaskets and check all seals for serviceability.

2. Install the transmission onto Tooling (A).

3. Note the location of the transmission wiring harness and any associated brackets and set to the side.
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   Illustration 2	g03842227

4. Remove bolts (1), the washers, and the clips. Mark the location of the clips.

5. Remove torque converter housing (2) and the gasket. Discard the gasket.
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   Illustration 3	g03845629

6. Remove bolts (3) and the washers. Remove pump (4).

7. Inspect the pump for any wear or damage. Refer to "Reuse and Salvage Guidelines" , (CX38 Transmission Pump Inspection Guideline) for the correct inspection procedure.

   Note: Failure to inspect the pump may result in future pump failure.

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   Illustration 4	g03845633

8. Remove bolts (5) and the washers. Note the location of bolts (5). Remove cover (7) and the gasket. Discard the gasket.

9. Remove three bolts (6) and the washers.
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   Illustration 5	g06045516

   Note: Failure to install bolts (8) and (9) will result in the planetary falling upon rotation.

10. Reinstall bolt (8) and 3 washers. Ensure bolt (9) is installed with one washer.

11. Use Tooling (A) and rotate the transmission 180 degrees.
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    Illustration 6	g03847042

12. Remove output speed sensor assemblies (10).
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    Illustration 7	g03847186

    Note: Thrust buttons (eight total) may stick to the bottom the planet carrier assembly when removing.

13. Attach a suitable lifting device to yoke assembly (11). The combined weight of yoke assembly (11) and the rear cover assembly is approximately 68 kg (150 lb).

14. Remove bolts (12) and the washers. Remove yoke assembly (11) and the rear cover assembly as a unit. Remove and discard the gasket.
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    Illustration 8	g03847496

15. Remove bolt (13) and the washer, two O-ring seals, and the plate. Remove wear sleeve (14) from yoke assembly (11).
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    Illustration 9	g03847506

16. Use a suitable press to remove carrier assembly (15) from the rear cover assembly.
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    Illustration 10	g03847542

17. Remove lip seal (16). Remove bearing cone and two bearing cups (17).
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    Illustration 11	g03847644

18. Remove retaining ring (18) and retainer (19).

19. Remove bearing cone (20) and spacer (21).
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    Illustration 12	g03847720

20. Remove retaining ring (22) and bearing (23).

21. Remove roll pin (24).
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    Illustration 13	g03847725

22. Remove bolts (25) and rotor sensor (26).
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    Illustration 14	g03847741

23. Push spring pin (28) into shaft (27).
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    Illustration 15	g03847783

24. Remove shaft (27) from carrier assembly (29).

25. Remove gear (32) and thrust washers (30) and (34).

26. Remove bearings (31) and (33).

27. Repeat Steps 22 through 25 for the remaining carrier gear assemblies.
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    Illustration 16	g03848079

28. If necessary, remove eight thrust buttons (35).

29. Compress retaining ring (36) and remove ring gear (37).

30. Remove retaining ring (36).
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    Illustration 17	g03848299

31. Remove plate (38).
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    Illustration 18	g03848359

32. Remove five (clutch No. 4) friction discs (39) and four clutch plates (40).
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    Illustration 19	g03848519

33. Remove five springs (42) and plate (43).

34. Remove five dowel pins (41).
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    Illustration 20	g03848531

    Note: Thrust buttons (eight total) may stick to the bottom the carrier assembly when removing.

35. Attach a suitable lifting device to carrier assembly (44). The weight of carrier assembly (44) is approximately 34 kg (75 lb).

36. Remove carrier assembly (44).
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    Illustration 21	g03848560

37. Compress retaining ring (46) and remove hub (45).

38. Remove retaining ring (46).
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    Illustration 22	g03848983

39. Push spring pin (48) into shaft (47).
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    Illustration 23	g03849008

40. Remove shaft (47) from carrier assembly (55).

41. Remove gear (52) and thrush washers (50) and (54).

42. Remove bearings (51) and (53).

43. Repeat Steps 38 through 41 for the remaining carrier gear assemblies.

44. Remove bearing sleeve (49).
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    Illustration 24	g03849065

45. If necessary, remove eight thrust buttons (56).

46. Remove 12 bolts (57).
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    Illustration 25	g03849073

47. Reposition four bolts (57) and squeeze bolts (57) when lifting to remove piston housing (58) and piston (59).

    Note: Removing the piston housing can also be accomplished by gripping the ring gear and removing the piston housing and gear at once. Also note that a plate from the next clutch pack could stick to the bottom of the piston.

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    Illustration 26	g03849100

48. Install Tooling (B) and a suitable lifting device. Slowly remove (Clutch No. 5) clutch housing assembly (60).
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    Illustration 27	g03849128

49. Remove ring gear (61). Remove springs six (63) and six dowel pins (62).
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    Illustration 28	g03849144

50. Remove three clutch plates (64) and three friction discs (65).

    Note: Top plate (64) may stick to the bottom of piston housing (58).

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    Illustration 29	g03849162

51. Remove thrust washer (67).

52. Remove piston (66) and the two ring seals from clutch housing (68).
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    Illustration 30	g03849181

53. Remove O-ring seals (69).

54. Remove cover (71) and two intermediate speed sensor assemblies (70) and (72).
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    Illustration 31	g03849273

55. Attach a suitable lifting device to transmission housing (73). The weight of the transmission housing and planetary is approximately 340 kg (750 lb).

56. Remove transmission housing and planetary (73) from Tooling (A) and secure onto Tooling (C).
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    Illustration 32	g03849202

57. The weight of transmission housing (73) is approximately 113 kg (250 lb).

58. Remove bolts (8) and (9) and the washers that were previously installed.
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    Illustration 33	g03849260

59. Remove transmission housing (73) and secure back onto Tooling (A). Remove the gasket and discard.

    Note: The housing is piloted on the planetary.

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    Illustration 34	g06038399

60. Remove shaft (74) and ring seals from shaft (74).
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    Illustration 35	g03858284

    Note: Thrust buttons (eight total) may stick to the bottom of gear assembly (77) when removing.

61. Remove seals (78).

62. Remove gear (76) and gear assembly (77) as a unit.
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    Illustration 36	g03858295

63. Remove retaining ring (79) and gear (76) from gear assembly (77).
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    Illustration 37	g03849548

    Note: Thrust buttons (eight total) may stick to the bottom of the carrier assembly when removing.

64. If necessary remove (eight) thrust buttons (80). Remove the retaining ring connecting carrier assembly (81) to the planetary. Remove carrier assembly (81).
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    Illustration 38	g03849561

65. Press spring pin (83) into shaft (82).
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    Illustration 39	g03849583

66. Remove shaft (82) from the carrier assembly.

67. Remove gear (87) and thrust washers (85) and (89).

68. Remove bearings (86) and (88).

69. Repeat Steps 64 through 67 for the remaining carrier gear assemblies.

70. Remove bearing sleeve (84).

71. Remove retaining ring (91) to separate the carrier assembly and cylinder (90).
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    Illustration 40	g03849620

72. Remove (eight) thrust buttons (92) if necessary. Remove clutch No. 2 assembly (93).
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    Illustration 41	g03849636

    Note: Thrust buttons (eight, total) may have stuck to the bottom of this clutch assembly when removing from top of carrier assembly (109).

73. Remove retaining ring (94) and gear assembly (95).
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    Illustration 42	g03849651

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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.

74. If necessary remove (eight) thrust buttons (97).

    Note: Discard retaining ring (96).

75. Use Tooling (D) to compress plate (98). Remove retaining ring (96). Slowly decompress plate (98). Remove plate (98) and the O-ring seal and ring seal.
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    Illustration 43	g03849705

76. Remove retaining ring (99). Remove clutch piston (100) and the ring seal.
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    Illustration 44	g03849713

77. Remove spring (103). Remove three clutch plates (101) and three friction discs (102).
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    Illustration 45	g03849726

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    Illustration 46	g06038454

78. Remove end clutch plate (104). Remove retaining ring (108) to separate clutch housing (105) and hub (107). Remove the gear from hub (107). Remove retaining ring (106) from the gear and discard retaining ring (106).

    Note: Retaining ring (108) only needs removed if hub (106) needs removed.

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    Illustration 47	g06140734

79. If necessary, remove bearings (105A) and (105B).
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    Illustration 48	g06042408

80. Remove seals (111a) and retaining ring (110).

81. Attach a suitable lifting device and Tooling (B) to carrier assembly (109).

82. Apply slight upward pressure on carrier assembly (109). When the main shaft rises, use a dead blow hammer lightly to reseat the shaft. Repeat this process until carrier assembly (109) is free from the main shaft.

83. Remove carrier assembly (109).
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    Illustration 49	g03849806

84. Remove ring seals (113). Compress retaining ring (111) and remove gear (112). Remove retaining ring (111).
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    Illustration 50	g03849902

85. Remove (eight) thrust buttons (114). Thrust buttons (114) may have stuck to the bottom of clutch assembly (93).

86. Push spring pin (116) into shaft (115).
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    Illustration 51	g03849932

87. Remove shaft (115) from carrier (121).

88. Remove gear (119) and two thrust washers (117) and (120).

89. Remove bearing (118)

90. Repeat Steps 84 through 87 for the remaining gear assemblies.
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    Illustration 52	g03850057

91. Remove O-ring seals (124).

92. Remove retaining ring (122) and clutch No. 3 end plate (123).
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    Illustration 53	g03850073

93. Remove four friction discs (125) and four clutch plates (126).

94. Attach a suitable lifting device to the clutch piston assembly by removing two (M6) bolts 180º apart and attaching the suitable lifting device. Remove hub assembly (127) and clutch piston assembly together.
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    Illustration 54	g03850078

95. Remove retaining ring (128) and clutch piston assembly (129).
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    Illustration 55	g03850139

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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.

96. Remove 24 screws (130) and balance piston (131).
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    Illustration 56	g03850511

97. Remove plate (133) and two springs (132).

    Note: Not the orientation of springs (132).

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    Illustration 57	g03850519

98. Remove piston (134) and the inner ring seal on the housing and outer ring seal on piston (134). Discard the ring seals.
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    Illustration 58	g03850542

99. Remove (eight) thrust buttons (135).

100. Repeat Steps 94 though 96 for the opposite side.
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     Illustration 59	g03850571

101. If necessary, remove set screw (137) and pin (138). Repeat for the opposite side.
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     Illustration 60	g03850580

102. Remove hub (142).

103. Remove the retaining ring. Remove three No. 1 clutch plates (140) and three friction discs (141).
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     Illustration 61	g03850700

104. Remove clutch plate (143).
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     Illustration 62	g03850744

     Note: Mark orientation of bearing (145).

105. Remove bearing (145) and ring seals (146).

106. Remove retaining ring (144) and hub assembly (147).

     Note: Lifting on the center shaft will aid in removing retaining ring (144). Do not lift with lifting eye as damage to the shaft may occur.

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     Illustration 63	g03858186

107. Remove retaining ring (148) and plate (149).

108. Remove clutch No. 6 six friction disks (150) and six clutch plates (151).
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     Illustration 64	g03850802

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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.

109. Remove 26 bolts (152) and the washers. Remove hub (153) and the gasket. Discard the gasket.
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     Illustration 65	g03850828

110. Remove 16 springs (154) and 21 springs (155).
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     Illustration 66	g03850860

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     Illustration 67	g06292825

111. Remove inner low-gain piston (156), the ring seals, and the O-ring seal.

112. Remove outer high-gain piston (157), the ring seal, and O-ring seal.
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     Illustration 68	g03850908

113. Remove main shaft (158) and the ring seals.
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     Illustration 69	g03850885

114. Remove bearing (159) and mark the orientation. Remove seals (160) and (162).

     Remove bolts (161) and the washers (note the size and location. Remove housing (163) and the gasket. Discard the gasket. Remove roller bearing inside housing (163).

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     Illustration 70	g03850921

115. Remove outer ring seal (166).

116. Remove 11 bolts (164). Remove housing (165) and the gasket underneath. Discard the gasket.
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     Illustration 71	g03850927

117. Remove hub assembly (167) the O-ring seal and the gasket underneath. Discard the gasket.