16M Motor Grader Power Train Transmission - Disassemble Caterpillar


Transmission - Disassemble
`
1.1. Disassembly Procedure

Disassembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
138-7575  Link Bracket 
1U-9202  Lever Puller Hoist 
1P-2420  Transmission Repair Stand 
4C-8156  Lifting Fixture 
FT-2769  Table 
1U-6410  Three Jaw Puller 
9U-7480  Compressing Tube 
5P-7970 Nut 
8T-4224 Hard Washer 
- Bolt
M8 - 1.25 by 460 mm 
1U-6415  Three Jaw Puller 
9U-7480  Compressing Tube 
8T-4133 Nut 
8T-4121 Washer 
- Bolt
M10 - 1.5 by 460mm 
189-0408  Shackle As 
3E-3882  Eyebolt 
9U-7480  Compressing Tube 
6V-8149 Nut 
5P-8245 Hard Washer 
- Bolt
M12- 1.75 by 460 mm 

Start By:

  1. Remove the transmission. Refer to Disassembly and Assembly, "Transmission - Remove".


NOTICE

Keep all parts clean from contaminants.

Contaminants may cause rapid wear and shortened component life.




    Illustration 1g01390304

  1. Position transmission (1) onto suitable cribbing. The weight of transmission (1) is approximately 1043 kg (2300 lb).


    Illustration 2g01390307

  2. Remove clip (2). Remove hose assembly (3). Remove tube assembly (4). Remove tube assembly (5). Remove tube assembly (6).


    Illustration 3g01390308

  3. Disconnect harness assembly (7). Remove bolts (8) to remove filter base (9).


    Illustration 4g01390309

  4. Remove yoke assembly (10).


    Illustration 5g01390315

  5. Remove retaining ring (11).

  6. Remove cup (12). Remove O-ring seal (13).


    Illustration 6g01390318

  7. Remove bolts (14) to remove control module (15) and spacers (16).


    Illustration 7g01390322

  8. Use Tooling (A), Tooling (B), and a suitable lifting device to position transmission (1) with the output shaft upward.


    Illustration 8g01390323

    ------ WARNING! ------

    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.


  9. Remove bolts (17) evenly to remove spring plate (18).


    Illustration 9g01390327

  10. Remove lip seal (19).


    Illustration 10g01390329

  11. Remove O-ring seal (20).


    Illustration 11g01390331

  12. Remove spring discs (21).


    Illustration 12g01390334

  13. Remove piston (22).


    Illustration 13g01390338

  14. Remove piston seal (23). Remove piston seal (24).


    Illustration 14g01390339

  15. Disconnect harness assembly (25) and harness assembly (26).


    Illustration 15g01390342

  16. Remove bolts (27). Use two people to remove housing (28). The weight of housing (28) is approximately 27 kg (60 lb).


    Illustration 16g01390343

  17. Remove pressure sensor (29) and the O-ring seal. Remove solenoid (30).


    Illustration 17g01390345

  18. Remove O-ring seal (31), O-ring seal (32), O-ring seal (33), O-ring seal (34), and O-ring seal (35).


    Illustration 18g01390349

  19. Remove seal (36).


    Illustration 19g01390351

  20. Remove discs (37) and plates (38).

    Note: Note the quantity and the order of discs (37) and plates (38) for installation purposes.

  21. Remove O-ring seals (39) and O-ring seal (40).


    Illustration 20g01390352

  22. Remove retaining ring (41). Remove hub (42).


    Illustration 21g01390353

  23. Use Tooling (A), Tooling (B), and a suitable lifting device to position transmission (1) onto Tooling (C) with the output shaft downward. The weight of transmission (1) is approximately 1043 kg (2300 lb).


    Illustration 22g01390355

  24. Remove bolt (43) to remove speed sensor (44).


    Illustration 23g01390356

  25. Remove bolts (45) to remove speed sensor (46) and speed sensor (47).


    Illustration 24g01390359

  26. Remove cover (48).


    Illustration 25g01390360

  27. Remove bolts (49) to remove speed sensor (50) and speed sensor (51).


    Illustration 26g01390362

  28. Remove bolts (52).

  29. Use Tooling (A), Tooling (B), and a suitable lifting device to remove housing (53). The weight of housing (53) is approximately 261 kg (575 lb).


    Illustration 27g01390365

  30. Remove O-ring seal (54). Remove bolts (55). Remove tube assembly (56).


    Illustration 28g01390366

  31. Remove bolts (57) to remove seal carrier (58). Remove bolts (59) to remove seal carrier (60).


    Illustration 29g01390367

  32. Remove seal rings (61). Remove O-ring seals (62). Repeat this step for the remaining seal carrier.


    Illustration 30g01390368


    Illustration 31g01390372

  33. Use Tooling (D) and a suitable lifting device to remove clutch assembly (63) and clutch assembly (64). The weight of clutch assembly (63) and clutch assembly (64) is approximately 204 kg (450 lb).

  34. Position clutch assembly (63) and clutch assembly (64) onto Tooling (E). If necessary, support clutch assembly (63) with suitable blocking.

  35. Remove Tooling (D) to separate clutch assembly (63) from clutch assembly (64).


    Illustration 32g01390376

  36. Use Tooling (F) to remove bearing (65) and rotor (66).


    Illustration 33g01390377

  37. Remove thrust washer (67). Remove gear (68).


    Illustration 34g01390381

  38. Remove bearing sleeves (69) from gear (68).


    Illustration 35g01390383

  39. Remove thrust washer (70).


    Illustration 36g01390389

    ------ WARNING! ------

    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 (G) to compress spring (71). Remove retaining ring (72). Remove Tooling (G). Remove retainer (73). Remove spring (71).


    Illustration 37g01390392

  41. Remove slider (74).


    Illustration 38g01390395

  42. Remove retaining ring (75) to remove end plate (76).


    Illustration 39g01390400

  43. Remove discs (77) and plates (78).

    Note: Note the quantity and the order of discs (77) and plates (78) for installation purposes.



    Illustration 40g01390403

  44. Remove piston (79).


    Illustration 41g01390405

  45. Remove seal ring (80).


    Illustration 42g01390409

  46. Remove seal ring (81) and O-ring seal (82).


    Illustration 43g01390412

  47. Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 104 kg (230 lb).


    Illustration 44g01390413

  48. Use Tooling (H) to remove bearing (83).


    Illustration 45g01390414

  49. Remove spacer (84) and thrust washer (85).

  50. Remove gear (86).


    Illustration 46g01390419

  51. Remove bearing sleeves (87) from gear (86).


    Illustration 47g01390420

  52. Remove thrust washer (88).


    Illustration 48g06210691

    ------ WARNING! ------

    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.


  53. Use Tooling (M) to compress spring (89). Remove retaining ring (90). Remove Tooling (M). Remove retainer (91). Remove spring (89).


    Illustration 49g01390425

  54. Remove retaining ring (92) to remove end plate (93).


    Illustration 50g01390426

  55. Remove discs (94) and plates (95).

    Note: Note the quantity and the order of discs (94) and plates (95) for installation purposes.



    Illustration 51g01390428

  56. Remove piston (96).


    Illustration 52g01390430

  57. Remove seal ring (97).


    Illustration 53g01390540

  58. Remove seal ring (98) and O-ring seal (99).


    Illustration 54g01390545

  59. Use Tooling (H) to remove bearing (100) from clutch assembly (63).


    Illustration 55g01390547

  60. Remove thrust washer (101). Remove gear (102).


    Illustration 56g01390549

  61. Remove thrust washer (103). Remove gear (104).


    Illustration 57g01390554

  62. Remove bearing sleeve (105) from gear (104).


    Illustration 58g01390555

  63. Use Tooling (G) to compress spring (106). Remove retaining ring (107). Remove Tooling (G). Remove retainer (108). Remove spring (106).


    Illustration 59g01390562

  64. Remove retaining ring (109) to remove end plate (110).


    Illustration 60g01390565

  65. Remove hub (111).

  66. Remove discs (112) and plates (113).

    Note: Note the quantity and the order of discs (112) and plates (113) for installation purposes.



    Illustration 61g01390572

  67. Remove slider (114). Remove piston (115).


    Illustration 62g06497026

  68. Remove O-ring seal (250) and seal ring (251) from piston (115).


    Illustration 63g01390578

  69. Remove seal ring (118) and O-ring seal (119).


    Illustration 64g01390580

  70. Use a suitable lifting device to turn over clutch assembly (64). The weight of clutch assembly (64) is approximately 113 kg (250 lb).


    Illustration 65g01390581

  71. Use Tooling (F) to remove bearing (120).


    Illustration 66g01390582

  72. Remove spacer (121). Remove gear (122).


    Illustration 67g01390583

  73. Remove spacer (123). Remove thrust washer (124).


    Illustration 68g01390584

  74. Remove gear (125).


    Illustration 69g01390586

  75. Remove bearing sleeves (126) from gear (125).


    Illustration 70g01390588

  76. Remove thrust washer (127).


    Illustration 71g06210695

    ------ WARNING! ------

    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.


  77. Use Tooling (G) to compress spring (128). Remove retaining ring (129). Remove Tooling (G). Remove retainer (130). Remove spring (128).


    Illustration 72g01390592

  78. Remove retaining ring (131) to remove end plate (132).


    Illustration 73g01390593

  79. Remove hub (133).

  80. Remove discs (134) and plates (135).


    Illustration 74g01390595

  81. Remove slider (136). Remove piston (137).


    Illustration 75g01390596

  82. Remove seal ring (138).


    Illustration 76g01390597

  83. Remove seal ring (139) and O-ring seal (140).


    Illustration 77g02521756

  84. Remove seal ring (140A). Use Tooling (F) to remove bearing (140B) and spacer (140C). Remove gear (140D).


    Illustration 78g01390601

  85. Remove bolts (141). Remove seal carrier (142).


    Illustration 79g01390603

  86. Remove seal rings (143). Remove O-ring seals (144).


    Illustration 80g01390604

  87. Use Tooling (K), Tooling (L), and a suitable lifting device to remove clutch assembly (145). The weight of clutch assembly (145) is approximately 86 kg (190 lb).


    Illustration 81g01390606

  88. Position clutch assembly (145) onto Tooling (E).


    Illustration 82g01390608

  89. Use Tooling (H) to remove bearing (146).

  90. Remove spacer (147). Remove thrust washer (148).


    Illustration 83g01390612

  91. Remove gear (149).


    Illustration 84g01390614

  92. Use a suitable press to remove bearing (150) from gear (149).


    Illustration 85g01390620

  93. Remove thrust washer (151).


    Illustration 86g01390617

    ------ WARNING! ------

    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.


  94. Use Tooling (G) to compress spring (152). Remove retaining ring (153). Remove Tooling (G). Remove retainer (154). Remove spring (152).


    Illustration 87g01390622

  95. Remove retaining ring (155) to remove end plate (156).


    Illustration 88g01390625

  96. Remove slider (157).

  97. Remove discs (158) and plates (159).

    Note: Note the quantity and the order of discs (158) and plates (159) for installation purposes.



    Illustration 89g01390627

  98. Remove piston (160).


    Illustration 90g01390629

  99. Remove seal rings (161).


    Illustration 91g02407538

  100. Remove seal ring (161A) and O-ring seal (161B).


    Illustration 92g01390632

  101. Use a suitable lifting device to turn over clutch assembly (145). The weight of clutch assembly (145) is approximately 86 kg (190 lb).


    Illustration 93g01390633

  102. Use Tooling (H) to remove race (162). Remove thrust race (163). Remove thrust washer (164) and thrust washer (165).


    Illustration 94g01390634

  103. Remove gear (166).


    Illustration 95g01390639

  104. Use a suitable press to remove bearing (167) from gear (166).


    Illustration 96g01390641

  105. Remove thrust washer (168).


    Illustration 97g06210699

    ------ WARNING! ------

    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.


  106. Use Tooling (J) to compress spring (169). Remove retaining ring (170). Remove Tooling (J). Remove retainer (171). Remove spring (169).


    Illustration 98g01390646

  107. Remove retaining ring (172) to remove end plate (173).


    Illustration 99g01390647

  108. Remove slider (174).

  109. Remove discs (175) and plates (176).

    Note: Note the quantity and the order of discs (175) and plates (176) for installation purposes.



    Illustration 100g01390651

  110. Remove piston (177).


    Illustration 101g01390652

  111. Remove seal rings (178).


    Illustration 102g01391047

  112. Remove seal ring (179) and O-ring seal (180).


    Illustration 103g01390655

  113. Remove bolts (181) to remove seal carrier (182).


    Illustration 104g01390657

  114. Remove seal rings (183). Remove O-ring seals (184).


    Illustration 105g01390658

  115. Use Tooling (K), Tooling (L), and a suitable lifting device to remove clutch assembly (185). The weight of clutch assembly (185) is approximately 68 kg (150 lb).


    Illustration 106g01390662

  116. Position clutch assembly (185) onto Tooling (E).


    Illustration 107g01390666

  117. Use Tooling (F) to remove bearing (186).


    Illustration 108g01390668

  118. Remove spacer (187). Remove gear (188).


    Illustration 109g01390671

  119. Remove spacer (189). Remove slugs (190). Remove spacer (191).


    Illustration 110g01390672

  120. Remove thrust washer (192). Remove gear (193).


    Illustration 111g01390676

  121. Remove bearing sleeves (194) from gear (193).


    Illustration 112g01390680

  122. Remove thrust washer (195).


    Illustration 113g01390682

    ------ WARNING! ------

    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.


  123. Use Tooling (G) to compress spring (196). Remove retaining ring (197). Remove Tooling (G). Remove retainer (198). Remove spring (196).


    Illustration 114g01390949

  124. Remove retaining ring (199) to remove end plate (200).


    Illustration 115g01390685

  125. Remove slider (201).

  126. Remove discs (202) and plates (203).

    Note: Note the quantity and the order of discs (202) and plates (203) for installation purposes.



    Illustration 116g01390686

  127. Remove piston (204).


    Illustration 117g01390688

  128. Remove seal ring (205).


    Illustration 118g01390689

  129. Remove seal ring (206) and O-ring seal (207).


    Illustration 119g01390946

  130. Use a suitable lifting device to turn over clutch assembly (185). The weight of clutch assembly (185) is approximately 68 kg (150 lb).


    Illustration 120g01390863

  131. Use Tooling (H) to remove race (208). Remove thrust race (209). Remove thrust washer (210). Remove thrust washer (211).


    Illustration 121g01390871

  132. Remove gear (212).


    Illustration 122g01390872

  133. Use a suitable press to remove bearing (213) from gear (212).


    Illustration 123g01390877

  134. Remove thrust washer (214).


    Illustration 124g06210706

    ------ WARNING! ------

    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.


  135. Use Tooling (J) to compress spring (215). Remove retaining ring (216). Remove Tooling (J). Remove retainer (217). Remove spring (215).


    Illustration 125g01390880

  136. Remove retaining ring (218) to remove end plate (219).


    Illustration 126g01390883

  137. Remove slider (220).

  138. Remove discs (221) and plates (222).

    Note: Note the quantity and the order of discs (221) and plates (222) for installation purposes.



    Illustration 127g01390885

  139. Remove piston (223).


    Illustration 128g01390887

  140. Remove seal rings (224).


    Illustration 129g01390889

  141. Remove seal ring (225) and O-ring seal (226).


    Illustration 130g02517216
    Input Shaft

  142. Use a suitable lifting device to remove shaft assembly (227). The weight of shaft assembly (227) is approximately 36 kg (80 lb).


    Illustration 131g02517356

  143. Use a suitable lifting device to position shaft assembly (227) onto Tooling (E).

  144. Use suitable blocking to support shaft assembly (227). Use Tooling (H) to remove race (228).

  145. Remove gear (229).


    Illustration 132g02517358

  146. Remove bolts (230). Use bolts (230) to remove gear (231).


    Illustration 133g02517359

  147. Remove retaining ring (232). Remove bearing (233). Remove retainer (234).


    Illustration 134g02517360

  148. Remove retaining ring (235).

  149. Remove gear (236).


    Illustration 135g02517362

  150. Remove retaining ring (237). Remove bearing (238).


    Illustration 136g02517376

  151. Remove O-ring seal (239).


    Illustration 137g02517378

  152. Remove races (240) and races (241) from housing (54).


    Illustration 138g02517380

  153. Remove covers (242) and covers (243) from housing (54).


    Illustration 139g02517381

  154. Remove bearings (244), race (245), and race (246) from housing (247).