424B Disassembly and Assembly (Transmission) (RESM3578-02)

RESM3578-03
June 2010
Disassembly and
Assembly
424B Backhoe Loader
Power Train
JRC02961 - 5545 (Machine)
Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.
The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are, therefore, not all inclusive. If a tool, procedure
work method or operating technique that is not specifically recommended by Caterpillar isused,
you must satisfy your self that it is safe for you and for others. You should also ensure that the
product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts or parts with equivalent speci-
fications including, but not limited to, physical
dimensions, type, strength and material.
Failure to heed this warning can lead to prema-
ture failures, product damage, personal injury
or death.
3
Power Train
Table of Contents
Table of Contents
Disassembly and Assembly
Section
System Pressure - Release .................................5
Solenoid Valve (Transmission) - Remove ............5
Solenoid Valve (Transmission) - Disassemble ....6
Solenoid Valve (Transmission) - Assemble ..........7
Solenoid Valve (Transmission) - Install ................8
Transmission (Direct Drive) - Remove ................. 9
Transmission (Direct Drive) - Disassemble ....... 11
Transmission (Direct Drive) - Assemble ........... 17
Transmission (Direct Drive) - Install .................. 23
Drive Shaft – Remove and Install ..................... 25
Parking Brake - Remove and Install ................. 26
Front Axle - Remove ......................................... 29
Front Axle - Install ............................................. 30
Front Axle - Disassembly .................................. 31
Front Axle - Assembly ....................................... 33
Tie Bar (Steering) - Remove and Install ............ 36
Steering Cylinder - Removal Procedure ........... 37
Steering Cylinder - Disassembly Procedure ..... 38
Steering Cylinder - Assembly Procedure .......... 40
Steering Cylinder - Installation Procedure ........ 41
Rear Axle - Remove .......................................... 42
Rear Axle - Install .............................................. 43
Rear Axle - Disassembly Special
Recommendations forrepair operations ............ 45
Flange Group - Disassembly and Assembly ..... 49
Epicyclic Reduction Gear Group - Disassembly
and Assembly .................................................... 50
Wheel Hub Group - Disassembly and
Assembly .......................................................... 53
Axle Beam Trumpet Group - Disassembly and
Assembly .......................................................... 57
Brake Group - Disassembly and Assembly ...... 61
Brake Control Group - Disassembly and
Assembly............................................................ 67
Differential Support Group - Disassembly and
Assembly............................................................ 76
Differential Group - Disassembly and Assembly 83
Pinion Group Disassembly and Assembly ........ 86
Testing After Assembly ...................................... 92
Special Tools (Rear Axle) .................................. 93
Tyre and Rim (Front) – Remove and Install ...... 96
Tyre and Rim (Rear) – Remove and Install ...... 97
Index Section
Index......... ........................................................ 98
4
Power Train
Table of Contents
Accidental machine starting can cause injury or

death to personnel working on the machine.
To avoid accidental machine starting, turn the

battery disconnect switch to the OFF position and
remove the key. If the machine is not equipped
with a battery disconnect switch, disconnect the
battery cables from the battery and tape the bat-
tery clamps.
Place a do not operate tag at the battery discon-

nect switch location to inform personnel that the
machine is being worked on.
5
Power Train
Disassembly and Assembly Section
Disassembly and Assembly Solenoid Valve (Transmission)

Section - Remove
SMCS Code: 5479-011-T3
System Pressure - Release Removal Procedure for Direct Drive

Solenoid Valve
SMCS Code: 4250-553-PX; 4300-553-PX;
5050-553-PX
Release Procedure Personal injury can result from hydraulic oil pressure
and hot oil.
Hydraulic oil pressure can remain in the hydraulic

system after the engine has been stopped. Serious
Personal injury can result from hydraulic oil pressure
injury can be caused if this pressure is not released
and hot oil.
before any service is done on the hydraulic
system.
Make sure all of the attachments have been lowered,
injury can be caused if this pressure is not released
oil is cool before removing any components
before any service is done on the hydraulic
or lines. Remove the oil filler cap only when the en-
system.
gine is stopped, and the filler cap is cool enough
to touch with your bare hand.
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
1. Lower the implements to the ground.
any compartment or disassembling any component
containing fluids.
2. Shut off the engine.
Refer to Special Publication, NENG2500, “Caterpillar
3. Move the control levers through the full range of
Tools and Shop Products Guide” for tools and supplies
travel. This will relieve any pressure that may be
suitable to collect and contain fluids on Caterpillar
present in the implement hydraulic system.
products.
4. Depress the brake pedal repeatedly. This will
Dispose of all fluids according to local regulations and
relieve any pressure that may be present in the
mandates.
brake hydraulic system.
5. Slowly loosen the filler cap in order to release

the pressure.
6. Tighten the filler cap.
7. The pressure in the hydraulic system has

been released. Lines and components can be
removed.
6
Power Train
Note: The transmission has been removed for Solenoid Valve (Transmission)
photographic purposes.
- Disassemble
Disassembly Procedure
Start By:
a. Remove the transmission solenoid valve. Refer

to Disassembly and Assembly, Solenoid Valve
(Transmission) - Remove.
NOTICE
Illustration 1 Care must be taken to ensure that fluids are contained
1. Remove the floorplate. adjusting and repair of the product. Be prepared to
containing fluids.

products.

mandates.
Note: Cleanliness is an important factor. Before

Illustration 2 the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This
2. Disconnect wiring harness (2). will help to prevent dirt from entering the internal
mechanism.
3. Remove four caps (3) and bolts under each cap.
4. Remove transmission solenoid valve (4).
Illustration 4
1. Remove nut (1).

Illustration 3
5. Check the four O-rings (5) for wear. Replace the

O-rings if the O-rings are in poor condition.
7
Power Train
Note: O-rings, gaskets, and seals should always be

replaced. A used O-ring may not have the same
sealing properties as a new O-ring. Use 1U-6396
O-Ring Assembly Compound during the assembly
procedure.
Illustration 5
2. Remove cover (2), O-ring seal (3), solenoid (4),

washer (5), and O-ring seal (6) from valve body
(7).
3. Repeat Steps 1 and 2 for the opposite side of Illustration 6

the transmission solenoid valve.
1. Install O-ring seal (6), washer (5), solenoid (4),
O-ring seal (3), and cover (2) on valve body (7).
Solenoid Valve (Transmission)

- Assemble
Assembly Procedure
NOTICE
Illustration 7
any compartment or disassembling any component 2. Install nut (1). Tighten nut (1) to a torque of
containing fluids. 5.6 ± .6 N·m (49.6 ± 5.3 lb in).
Refer to Special Publication, NENG2500, “Caterpillar 3. Repeat Steps 1 and 2 for the opposite side of
Tools and Shop Products Guide” for tools and supplies the transmission solenoid valve.
products. End By:
Dispose of all fluids according to local regulations and a. Install the transmission solenoid valve. Refer to
mandates. Disassembly and Assembly, Solenoid Valve
(Transmission) - Install.
assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts. Lint
may be deposited on the parts which may cause
later trouble. Inspect all parts. If any parts are worn
or damaged, use new parts for replacement.
8
Power Train
Solenoid Valve (Transmission) Note: The transmission has been removed for
photographic purposes.
- Install
Installation Procedure for Direct

Drive Solenoid Valve
Personal injury can result from hydraulic oil pressure

and hot oil.

Illustration 8
injury can be caused if this pressure is not released 1. Check the four O-rings (5) for wear. Replace the
before any service is done on the hydraulic O-rings if the O-rings are in poor condition.
system.
2. Install four caps (3) and bolts under each cap.
NOTICE
containing fluids.
Illustration 9
Tools and Shop Products Guide” for tools and supplies 3. Connect wiring harness (2).
products. 4. Install the transmission solenoid valve (4).

mandates.
Illustration 10
5. Install the floorplate (1).

9
Power Train
Transmission (Direct Drive) -

Remove
SMCS Code: 3030-011-DD
Removal Procedure
Table 1
Required Tools
Tool Part Part Description Qty
Illustration 12
Number
8S-7640 Stand 2 3. Place tooling (B) under front axle (2).
A 8S-7611 Tube 2
8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmission Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar 1
Assembly
Start By:
a. Remove the rear drive shaft. Refer to Disassembly

and Assembly, Drive Shaft (Rear) - Remove and
Install.
Illustration 13
b. Remove the piston pump. Refer to Disassembly
and Assembly, Piston Pump (Implement and
4. Remove inspection plate (3). Install tooling (E) in
Steering) - Remove.
order to support the engine.
1. Use a suitable lifting device in order to raise
the machine to a height of 91.4 mm (36 inch)
between the ground and the side step.
Illustration 14
5. Remove plug (4) and drain the transmission oil

Illustration 11 into a suitable container.
2. Place tooling (A) under rear frame (1).

10
Power Train
Illustration 18
Illustration 15
6. Remove four bolts (5).
7. Repeat Step 6 for the opposite side.
8. Remove two bolts (6).
Illustration 19
11. Support transmission (10) with tooling (C), as

shown.
12. Attach tooling (D) to tooling (C) and transmission

Illustration 16 (10) in order to maintain a good balance.
9. Disconnect three electrical connectors (7).
Illustration 20
Illustration 17 13. Remove twelve bolts (11).
10. Loosen bolt (8) and slide rod assembly (9) off 14. Carefully move transmission (10) away from the
the transmission lever. engine in order to clear the torque converter.
Lower transmission (10) to the ground.
11
Power Train
Transmission (Direct Drive) - Note: Cleanliness is an important factor. Before

the disassembly procedure, the exterior of the
Disassemble component should be thoroughly cleaned. This
will help to prevent dirt from entering the internal
SMCS Code: 3030-015-DD; 3066-015 mechanism.
Note: The transmission will be disassembled in

major components. The major components will then
Disassembly Procedure be disassembled.
Table 2
Required Tools
Number
A 1U-5750 Engine Stand 1
B 6V-2157 Link Bracket 1
9S-9152 Puller Assembly 1
C 5F-7465 Puller 1
3/8inch x 6inch Bolt 2
D 4C-3652 Spring Compressor 1
E 1U-6405 Puller 1
Illustration 21
F 4C-3802 Puller 1
G 8H-0663 Puller 1 1. Install transmission (1) on tooling (A).
G 5F-7465 Puller 1
H 8B-7551 Puller 1
H 6V-3010 Puller 1
I 137-8102 Spring Compressor 1
J 4C-3089 Puller 1
K 1P-1859 Snap Ring Pliers 1
Start By:
a. Remove the transmission. Refer to Disassembly

and Assembly, Transmission (Direct Drive) -
Remove.
Illustration 22
NOTICE
2. Remove Implement pump drive shaft (2) from
transmission (1).
containing fluids.

products.

mandates.
Illustration 23
12
Power Train
3. Remove plug (3). Drain the transmission oil

into a suitable container.
Illustration 27
2. Use tooling (C) in order to remove bearing cone

Illustration 24 (10).
4. Remove bolt (6), washer (5), and yoke (4).
Illustration 28
Illustration 25
3. Use tooling (E) in order to remove bearing cone
(11) and gear (12).
5. Attach tooling (B) to case (7). Attach a suitable
lifting device to tooling (B). Remove fourteen
bolts (8). Remove case (7) from the transmission.
(Direct Drive) Output Shaft (Front)

(If Applicable)
Illustration 29
4. Remove two roller bearings (13), spacer (14),

needle bearing (15), and thrust washer (16).
Illustration 26
1. Remove front output shaft (9).

13
Power Train
Illustration 30 Illustration 33
5. Remove retainer (17) and clutch pack (18). 8. Release piston (22) by blowing shop air into the
lube passage, as shown.
Illustration 31
Illustration 34
6. Use a suitable press and tooling (D) in order to
compress spring (19). Use tooling (K) in order to 9. Use a seal pick in order to remove the seals
remove snap ring (20). from piston (22).
(Direct Drive) Output Shaft (Rear)
Illustration 32
7. Remove snap ring (20), retainer (21), and spring Illustration 35

(19).
1. Remove screws (24) from each of the gearshift
rods (23).
14
Power Train
2. Remove plug (25). 5. Remove bearings (33), spacer (34), and

synchronizer (35).
Illustration 37
Illustration 40
3. Remove plug (25), O-ring (26), two springs (27),
and three balls (28). Remove two gearshift rods 6. Use tooling (F) in order to remove bearing (36)
(23) from shift forks (29). and gear (37). Remove synchronizer (38).
4. Use tooling (E) in order to remove bearing (30), 7. Use tooling (K) in order to remove snap ring (39).
gear (31), and gear (32). Remove gear (40) and housing (41).
15
Power Train
2. Use tooling (G) in order to remove bearings (45)

and (46).
(Direct Drive) Input Shaft
1. Remove the input shaft by hand for disassembly.
Illustration 42
8. Use tooling (E) in order to remove gear (42).
(Direct Drive) Shaft
1. Remove the shaft by hand for disassembly.

Illustration 45
2. Use tooling (H) in order to remove bearing (47).
Illustration 43
2. Use tooling (G) in order to remove bearings (43)

and (44).
Illustration 46
(Direct Drive) Reverse Shaft 3. Use tooling (K) in order to remove snap ring
(48). Remove spacer (49), needle bearing (50),
1. Remove the reverse shaft by hand for and gear (51).
disassembly.
Illustration 47
Illustration 44
4. Remove retainer (52) and clutch pack (53).
16
Power Train
5. Use tooling (I) and a suitable press in order to 8. Use tooling (J) in order to remove bearing (57)
compress spring (55). Use tooling (K) in order to and gear (58).
remove snap ring (54). Remove the retainer and
spring (55).
Illustration 52
Illustration 49 9. Remove gear (59) from the clutch pack.
6. Release piston (56) by blowing shop air into the 10. Repeat Steps 4 through 7 for the remainder of
lube passage, as shown. the input shaft.
Transmission Case
Illustration 50
Illustration 53
7. Use a seal pick in order to remove the seals
from piston (56).
Note: Record the measurement and placement of
the shims behind the bearing cups in order to aid
in assembly.
17
Power Train
1. Remove bearing cups (60), (61), (62), (63), and Note: Install the shims behind each bearing cup
(64). that was recorded on the disassembly procedure.
1. Install bearing cups (60), (61), (62), (63), and

Transmission (Direct Drive) - (64).
Assemble (Direct Drive) Input Shaft

SMCS Code: 3030-016-DD; 3066-016
Assembly Procedure
Table 3
Required Tools
Number
A 137-8102 Spring Compressor 1
B 1P-1859 Snap Ring Pliers 1
C 4C-3652 Spring Compressor 1
D 6V-2157 Link Bracket 1 Illustration 55
E 8T-5096 Indicator 1
F 1U-5750 Engine Stand 1 1. Install the needle thrust bearings on the shafts.
The open end of cups (1) must point away from
Note: The transmission will be assembled in major the bearings or gears that are contacted.
components. The major components will then be
assembled.

assembly, all parts should be thoroughly cleaned
in cleaning fluid. Allow the parts to air dry. Wiping
cloths or rags should not be used to dry parts. Lint
may be deposited on the parts which may cause
later trouble. Inspect all parts. If any parts are worn
or damaged, use new parts for replacement.
Note: Apply a light film of clean transmission oil to

all components before assembly.
Illustration 56
Transmission case
2. Install the seals on piston (56).
Illustration 54
Illustration 57
18
Power Train
3. Install piston (56). Install the retainer and spring 7. Heat bearing cone (57) to 135 O C (275 O F). Install
(55). Use tooling (A) and a suitable press in bearing cone (57).
order to compress spring (55). Use tooling (B) in
order to install snap ring (54). 8. Install the input shaft.
(Direct Drive) Reverse Shaft
Illustration 58
4. Install clutch pack (53) and retainer (52). Illustration 61
5. Repeat Steps 2 through 4 for the opposite end 1. Heat bearing cones (45) and (46) to 135 O C
of the input shaft. (275 O F). Install bearing cones (45) and (46).
2. Install the reverse shaft.
(Direct Drive) Shaft
Illustration 59
6. Install gear (51), needle bearing (50), and spacer

(49). Use tooling (B) in order to install snap ring
(48).
Illustration 62
1. Heat bearing cones (45) and (46) to 135 O C

(275 O F). Install bearing cones (45) and (46).
2. Install the shaft.
Illustration 60
19
Power Train
(Direct Drive) Output Shaft (Rear)
Illustration 66
Illustration 63 4. Install synchronizer (35), spacer (34), and

bearings (33).
1. Install gear (42).
Illustration 67
Illustration 64
5. Install gear (31) and (32). Heat bearing cone
2. Install housing (41) and gear (40). Use tooling (30) to 135 O C (275 O F). Install bearing cone (30).
(B) in order to install snap ring (39).
6. Install the output shaft (rear) in the transmission.
Illustration 65
Illustration 68
3. Install synchronizer (38). Install gear (37). Heat
bearing cone (36) to 135 O C (275 O F). Install
bearing cone (36).
20
Power Train
7. Install two gearshift rods (23) on shift forks (29).

Install the gearshift rods in the transmission.
Install three balls (28), two springs (27), and
O-ring (26). Install plug (25).
Illustration 73
2. Install piston (22), spring (19), and retainer (21).
3. Use tooling (C) and a suitable press in order to

Illustration 70 compress spring (19). Use tooling (B) in order to
install snap ring (20).
8. Install screws (24) on each of the gearshift rods
(23).
(Direct Drive) Output Shaft (Front)

(If Applicable)
Illustration 74
4. Install clutch pack (18) and retainer (17).
Illustration 71
1. Install seals on piston (22).

21
Power Train
5. Install thrust washer (16), needle bearing (15), 8. Install front output shaft (9).
spacer (14), and two roller bearings (13).
Final Assembly
Illustration 76
Illustration 79
6. Heat bearing cone (11) to 135 O C (275 O F). Install
bearing cone (11). Note: Clean the mating surfaces of case (7). Apply
a continuous bead of Sealant to the mating surface
of the case.
1. Attach tooling (D) to case (7). Attach a suitable

lifting device to tooling (D). Use fourteen bolts
(8) in order to install case (7).
Illustration 77
7. Heat bearing cone (10) to 135 O C (275 O F). Install

bearing cone (10).
Illustration 80
22
Power Train
2. Install a bolt in the output shaft. The output

shaft must be fully seated. Install tooling (E), as
shown. Zero tooling (E). Pry up on the bolt and
record the reading on tooling (E). The reading
must be 0.03 mm (0.0012 inch) to 0.08 mm
(0.0031 inch). Add or remove shims in Step 1 in
the Case Assembly Procedure in order to obtain
the correct reading.
Illustration 83
5. Install plug (3).
Illustration 81
3. Repeat Step 1 for the input shaft and the output

shaft (front). Use the same tolerance for all of
the shafts. Remove the expansion plug in order
to check the input shaft. Use a screwdriver to
pry up on the input shaft. Install a new Expansion
Plug.
Illustration 84
6. Install Implement pump drive shaft (2) in

transmission (1).
Illustration 82
4. Install yoke (4), washer (5), and bolt (6).

Illustration 85
7. Remove transmission (1) from tooling (F).
End By:
a. Install the transmission. Refer to Disassembly

and Assembly, Transmission (Direct Drive) -
Install.
23
Power Train
Transmission (Direct Drive) - 2. Use tooling (C) in order to position transmission

(10).
Install
SMCS Code: 3030-012-DD
Installation Procedure
Table 4
Required Tools
Number
8S-7640 Stand 2
A 8S-7611 Tube 2 Illustration 88
8S-7615 Pin 2
B 1U-9760 Jack Stand 2 3. Install fourteen bolts (11).
C 1U-7505 Transmission Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar 1
Assembly
Illustration 89
4. Slide rod assembly (9) on the transmission lever

and tighten bolt (8) .
Illustration 86
1. Attach tooling (D) to tooling (C) and transmission

(10) in order to maintain a good balance.
Illustration 90
5. Connect three electrical connectors (7).
Illustration 87
24
Power Train
6. Install four bolts (5). 11. Remove tooling (B) from front axle (2).
7. Repeat Step 6 for the opposite side.
8. Install two bolts (6).
Illustration 95
12. Remove tooling (A) from rear frame (1).

Illustration 92
13. Fill the transmission with oil. Refer to Operation
9. Install plug (4). and Maintenance, Capacities for the proper
type and capacity of oil.
End By:
a. Install the piston pump. Refer to Disassembly

and Assembly, Piston Pump (Implement and
Steering) - Install.
b. Install the rear drive shaft. Refer to Disassembly

and Assembly, Drive Shaft (Rear) - Remove and
Install.
Illustration 93
10. Remove tooling (E). Install inspection plate (3).

25
Power Train
Drive Shaft – Remove and

Install
SMCS Code: 3253-010-RE
S/N:JRC02961-UP
Removal Procedure
Illustration 98
2. Tighten the bolts (1) in the sequence that is

indicated. Tighten bolts (1) to 25 ± 6 N.m
(18 ± 4 lb ft).
Illustration 96
1. Remove four bolts (1) and two collars (2). Remove

rear drive shaft (3).
Illustration 97
1. Install rear drive shaft (3). Install two collars (2)

and four bolts (1).
26
Power Train
Parking Brake - Remove and

Install
SMCS Code: 4267-010
S/N:JRC02961-UP
Removal Procedure
Illustration 101
Parking brake lever assembly
(4) Clip
(5) Pin
(6) Cable
(7) Clip
3. Remove clip (4) and pin (5). Squeeze clip (7)

together. Pull cable (6) out of the parking brake
assembly
Illustration 99
Illustration 102
Illustration 100 4. Remove four bolts (8) and parking brake lever
assembly (9).
1. Pull floormat (1) away from cover (2) in order to
expose the screws (3).
2. Remove screws (3) and cover (2).

27
Power Train
Illustration 105
Illustration 103
2. Install parking brake lever assembly (9) and install
Parking brake lever assembly is located on the rear axle
four bolts (8).
(10) Clip
(11) Pin
5. Remove clip (10) and pin (11) on both LH and RH

sides. Separate the cable from the lever.
Illustration 106
Parking brake lever assembly
(4) Clip
(5) Pin
(6) Cable
(7) Clip
3. Install cable (6) in the parking brake assembly.

Expand clip (7).
4. Install pin (5) and clip (4)

Illustration 104
Parking brake lever assembly is located on the rear axle
(10) Clip
(11) Pin
1. Install pin (11) and clip (10) on both LH and RH

sides.
28
Power Train
Illustration 107
Illustration 108
5. Install cover (2) and screws (3).
6. Reposition floormat (1).

29
Power Train
Front Axle - Remove

NOTICE
SMCS Code: 3282-011-FR; 4313-011-FR Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance,
S/N:JRC02961-UP testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
Removal Procedure before opening any compartment or disassembling
any component containing fluids.
Start By:
a. Remove the counterweight. Refer to Disassembly Tools and Shop Products Guide” for tools and supplies
and Assembly, “Counterweight - Remove and suitable to collect and contain fluids on Caterpillar
Install” for the correct procedure. products.
Table 11 Dispose of all fluids according to local regulations and
Required Tools mandates.
Tool Part Number Part Description Qty

1. Disconnect hydraulic lines from steering cylinder.
A 8S-7640 Stand 2
A 8S-7615 Pin 2
A 8S-8048 Saddle 2
A 8S-7611 Tube 2
B 4C-4089 Jack 1
Personal injury can result from hydraulic oil

pressure and hot oil.
Illustration 109
system after the engine has been stopped. Serious 2. Use the bucket in order to raise the front of the
injury can be caused if this pressure is not machine. Install tooling (A), as mentioned in the
released before any service is done on the table (11).
hydraulic system.
3. Place jack (tool - B) under axle (1).
Make sure all of the attachments have been
lowered, oil is cool before removing any 4. Remove the nut and bolt (2). Remove pin (3) from
components or lines. Remove the oil filler cap only the frame.
when the engine is stopped, and the filler cap is
cool enough to touch with your bare hand. 5. Lower jack (tool - B) and pull axle (1) away from
the machine.
30
Power Train
Front Axle - Install

SMCS Code: 3282-011-FR; 4313-012-FR
S/N:JRC02961-UP
Table 11A
Required Tools
A 8S-7640 Stand 2
A 8S-7615 Pin 2
A 8S-8048 Saddle 2
A 8S-7611 Tube 2
B 4C-4089 Jack 1
Illustration 110
1. Position jack (tool - B) and axle (1) under the

machine.
2. Raise axle (1). Install pin (3), nut and bolt (2).
Tighten the nut to 100 ± 20 N·m (74 ± 15 lb ft).
3. Remove jack (tool - B). Remove tooling (A), as

mentioned in the table (11A).
4. Lower the machine to the ground.
5. Connect hydraulic line to steering cylinder.
End By:
a. Install the counterweight. Refer to “Counterweight

- Remove and Install”.
31
Power Train
Front Axle - Disassembly

SMCS Code: 3282-015-FR; 4313-015-FR
S/N:JRC02961-UP
Table 12
Required Tools
A 1P-2322 Puller 1
Illustration 112
Start By:
3. Remove the bolts (3) and hub cap (4).
a. Remove the tie rods. Refer to Disassembly and
Assembly, “Tie bar - Remove” for the correct
procedure.
Illustration 113
4. Remove cotter pin (5), nut (6) and washer (7) from
the spindle shaft.
Illustration 111
1. Use the bucket to raise the machine. Place wood

blocks under the front axle in order to support the
machine.
2. Remove the washers, nuts (2), the tire and

wheel (1). The weight of the tire and wheel is
45 kg (100 lb).
Illustration 114
5. Remove O-ring seal (8) from the spindle shaft.

32
Power Train
8. Inspect wear sleeve (13) and inspect bearing

cup (12). Replace the cup if it is necessary.
Illustration 115
6. Remove bearing cone (10) and hub assembly (9). Illustration 118
9. Use tooling (A) in order to remove bearing

cone (14). Remove seal (15) from the spindle.
Illustration 116
7. Inspect bearing cup (11). Replace the cup if it is

necessary.
Illustration 119
10. Remove locknut (16), washer (17) and pin (18)

from the axle beam.
Illustration 117
33
Power Train
Front Axle - Assembly

SMCS Code: 3282-016-FR; 4313-016-FR
S/N:JRC02961-UP
Assembly Procedure
Illustration 120
11. Remove kingpin (19), spindle (20) and washers.
Illustration 122
1. Install bearing sleeves (21) in the spindle

assembly.
Note : Ensure the greasing hole of the bearing sleeve
is aligned with the hole in the spindle.
Illustration 121
12. Remove bearing sleeves (21) from the spindle

assembly. Replace the bearing sleeves if it is
necessary.
Illustration 123
2. Install washers, spindle (20) and kingpin (19).

34
Power Train
Illustration 126
Illustration 124
6. Install wear sleeve (13) and install bearing
3. Install pin (18), washer (17) and tighten the cup (12).
nut (16) to 55 ± 10 N·m (41 ± 7 lb ft).
Illustration 125
Illustration 127
4. Install the seal (15) to the spindle.
7. Install bearing cup (11).
5. Install bearing cone (14). Apply lubricating grease
to the inside diameter of cone (14).
35
Power Train
11. Back off adjusting nut to the nearest locking hole.

Install cotter pin (5) in the shaft.
Illustration 128
8. Install bearing cone (10) and hub assembly (9).

Illustration 131
12. Install hub cap (4) and bolt (3). Tighten the bolts
to 12 ± 3 N·m (9 ± 2 lb ft).
Illustration 129
9. Install O-ring seal (8) from the spindle shaft.
Illustration 132
13. Install the washers, nuts (2) tire and

wheel (1). The weight of the tire and wheel is
45 kg (100 lb).
14. Tighten nuts (2) to 400 ± 40 N·m (295 ± 30 lb ft).
15. Remove the wood blocks and lower the machine.
End By:
a. Install the tie bar and steering cylinder. Refer to

Disassembly and assembly, “Tie bar – Install” for
Illustration 130
the correct procedure.
10. Intall washer (7), nut (6) to the spindle shaft.

Tighten the nut to 100 N.m (74 lb.ft).
36
Power Train
Tie Bar (Steering) - Remove NOTE: Four wheel drive front axle group shown as
typical illustration for tie rod removal and installation
and Install procedure.
SMCS Code: 4318-010; 4318-010-ZH
S/N:JRC02961-UP
Removal Procedure
Table 13
Required Tools
Transmission Repair
A 1P-2420 1
Stand
Illustration 133
Start By:
a. Remove the axle from the machine. Refer to 1. Secure the axle onto tooling (A), as mentioned
Disassembly and Assembly, “Drive and Steering in table (13).
Axle (Front) - Remove”.

pressure and hot oil.

injury can be caused if this pressure is not
released before any service is done on the
hydraulic system.
Make sure all of the work tools have been lowered

to the ground, and the oil is cool before removing
any components or lines. Remove the oil filler cap Illustration 134
only when the engine is topped, and the filler cap
is cool enough to touch with your bare hand. 2. Remove bolts (1) on both ends.
NOTICE 3. Remove pin assembly (2) and move out the tie
bar (3) from spindle assembly – RH (4).
during performance of inspection, maintenance, 4. Install pin assembly (2) to retain the steering
testing, adjusting and repair of the product. Be cylinder (5) in place.
before opening any compartment or disassembling 5. Remove pin assembly (6) and tie bar (3).

products.

mandates.
37
Power Train
2. Remove pin assembly (2) from the spindle

assembly-RH (4) and install tie bar (3).
3. Install pin assembly (2) and pin assembly (6).
4. Install bolts (1) in the both ends. Tighten the bolts

to 28 ± 7 N·m (21 ± 5 lb ft).
End By:
a. Install the axle onto the machine. Refer to

Disassembly and Assembly, “ Drive and Steering
Axle (Front) – Install”.
Illustration 135
6. Remove bearing sleeves (7) from the tie bar.

Replace the bearing sleeves if it is necessary. Steering Cylinder - Removal
Procedure
SMCS Code: 4303-011
S/N:JRC02961-UP
Start By:
a. Remove the tie rods from the axle. Refer to

Disassembly and Assembly, “Tie Rod (Steering)
- Remove and Install”.

Illustration 136 pressure and hot oil.
1. Install bearing sleeves (7) in the tie bar. Hydraulic oil pressure can remain in the hydraulic
Note : Ensure the greasing hole of the bearing sleeve injury can be caused if this pressure is not
is aligned with the hole in the tie bar. released before any service is done on the
hydraulic system.

any components or lines. Remove the oil filler cap
only when the engine is stopped, and the filler cap
is cool enough to touch with your bare hand.
Illustration 137
38
Power Train
NOTICE Steering Cylinder -

Care must be taken to ensure that fluids are contained Disassembly Procedure
testing, adjusting and repair of the product. Be SMCS Code: 4303-015
before opening any compartment or disassembling S/N:JRC02961-UP
Start By:
Tools and Shop Products Guide” for tools and supplies a. Remove the steering cylinder from the axle. Refer
suitable to collect and contain fluids on Caterpillar to Disassembly and Assembly, “Steering Cylinder
products. - Removal Procedure”.
mandates. NOTICE
testing, adjusting and repair of the product. Be
before opening any compartment or disassembling

products.

mandates.
Table 14
Illustration 138 Required Tools
1. Remove bolts (1) on both ends. Sl.No Part Description Tool
2. Remove pin assembly (2) and pin assembly (3). 1 Head End Cover Spanner
3. Remove steering cylinder (4). 2 Piston Socket Size 32 mm
3 Hollow Pipe 2 Meter Long
4 Nylon Mallet 1 Meter Long
16 ± 2 N.m
5 Torque Wrench
(12 ± 1.5 lb ft)
6 Screw Driver Bent

39
Power Train
Illustration 139
Steering Cylinder
1. Place the steering cylinder in position on V blocks.

Insert a 2 meter pipe into the clevis bore.
2. Use C spanner and loosen the cylinder head (1)

from the cylinder body (2).
3. Removel the cylinder head (1) and the cylinder

rod (3) from the cylinder body (2).
4. Open the nut (4) using a proper tool. Remove the

piston (5) from the piston rod (3).
5. Remove seal (6), O-rings (7) & (8) and piston

bearing (9) from the piston (5).
6. Pull the cylinder rod (3) out of the cylinder

head (1).
7. Remove the seals (10) and (11), rings (12)

and (13), wiper (14), backup ring (15) and rod
seal (16) from the cylinder head (1).
40
Power Train
Steering Cylinder - Assembly NOTICE

Procedure Care must be taken to ensure that fluids are contained
SMCS Code: 4303-016 testing, adjusting and repair of the product. Be
S/N:JRC02961-UP before opening any compartment or disassembling

products.

mandates.
Illustration 140
Steering Cylinder
1. Install seals (10) and (11), rings (12) and (13), 4. Use hydraulic fluid to lubricate the sealing lips of
backup ring (15) and rod seal (16) onto the the seals.
cylinder head(1). Ensure that the seals and rings
5. Place the components of steering cylinder in
are oriented properly.
position to reassemble.
2. Apply hydraulic oil to the lip surface of the wiper
6. Install seal (6), O-rings (7) and (8) and piston
sear (14).
bearing (9) onto the piston (5).
3. Install the wiper seal (14) onto the cylinder
7. Install the piston (5) onto the cylinder
head (1). Ensure that the wiper seal are oriented
rod (3). Tighten the nut (4) to a torque
properly.
16 ± 2 N.m (12 ± 1.5 lb ft).
41
Power Train
8. Apply Loctite 242 / Anabond 118 onto the threads 1. Install steering cylinder (4) into the axle beam.
of the piston rod (3) and cylinder head (1).
2. Install pin assembly (2) and pin assembly (3).
9. Push the piston and rod assembly into the
cylinder body (2). Assemble the cylinder 1. Install bolts (1) onto the both pin assembly (2)
head (1) to cylinder body (2). and (3). Tighten the bolts (1) to a torque
28 ± 7 N·m (21 ± 5 lb ft).
End By:
End By:
a. Install the steering cylinder on to the machine.
Refer to Disassembly and assembly, “ Steering a. Install the tie bar onto the front axle. Refer to
Cylinder – Install”. Disassembly and assembly, “Tie Bar – Remove
and Install”.
Steering Cylinder - Installation

Procedure
SMCS Code: 4303-012-FR
S/N:JRC02961-UP
NOTICE

products.

mandates.
Illustration 141
42
Power Train
Rear Axle - Remove NOTICE

SMCS Code: 3278-011-RE; 3282-011-RE during performance of inspection, maintenance,
S/N: JRC02961-UP
Removal Procedure any component containing fluids.
Table 15
Required Tools Tools and Shop Products Guide” for tools and supplies
Tool Part Number Part Description Qty products.
A 1U-7505 Jack 1
mandates.
Start By:
a. Remove the tyre and rims. Refer to Disassembly

and Assembly, “Tyre and Rim (Rear) - Remove
and Install”
b. Remove the rear drive shaft. Refer to Disassembly

and Assembly, “Drive Shaft (Rear) - Remove and
Install”.

pressure and hot oil. Illustration 142
Hydraulic oil pressure can remain in the hydraulic 1. Disconnect two hoses (1) from the top of the axle.
system after the engine has been stopped. Serious fix the cap to the hoses.
injury can be caused if this pressure is not
released before any service is done on the
hydraulic system.

any components or lines. Remove the oil filler cap
only when the engine is stopped, and the filler cap
is cool enough to touch with your bare hand.
Illustration 143
2. Remove the differential lock linkage (2) (If fitted).

43
Power Train
Rear Axle - Install

SMCS Code: 3278-012-RE; 3282-012-RE
S/N: JRC02961-UP
Table 16
Required Tools
A 1U-7505 Jack 1
Illustration 144
3. Disconnect the parking brake lever assembly (3)

from the rear axle.
Illustration 146
1. Raise the axle using Jack (tool - A).
Illustration 145 2. Install the plates (3), bolts (2) and washers,
nuts (1). Tighten the bolts (2) to 460 ± 70 N.m
4. Place Jack (tool - A) under the axle. (339 ± 52 lb ft).
5. Remove nuts and washers (1), bolts (2) and

plates (3).
6. Lower the jack (tool - A) and pull the axle away

from the machine.
44
Power Train
Illustration 147
3. Connect the differential lock linkage (2) (If fitted).
Illustration 148
4. Connect two hoses (1) on the top of the axle.
End By:
a. Assemble the parking brake. Refer to

Disassembly and Assembly, “Parking Brake -
Remove and Install” for the correct procedure.
b. Install the rear drive shaft. Refer to Disassembly

and Assembly, “Drive Shaft (Rear) - Remove and
Install” in this manual.
c. Install tires and rims. Refer to Disassembly and

Assembly, “Tyre and Rim (Rear) - Remove and
Install” in this manual.
45
Power Train
Rear Axle - Disassembly

Special Recommendations for
repair operations
Before starting any disassembly and assembly
operations, read carefully the following
recommendations.
Shafts seals
Respect the following recommendations during shaft
seal assembly: Illustration 151
• Clean shaft very carefully and ensure that the part • Lubricate seal lips (use oil) and fill 3/4 of seal cavity
in contact with the shaft seal is not damaged, cut with grease).
or out of roundness.
• Do not damage the seals while assembling the

shaft.
Illustration 152
• Use appropriate drivers.
Illustration 149
Do not use a hammer directly on the seals.
O-rings
Illustration 150
• Assemble the seals so that the lip is fitted towards

the oil side.
Illustration 153
Lubricate adequately before inserting them at the right

place and avoid o-ring rolling while inserting the shaft.
46
Power Train
Adjusting shims
Respect the following recommendations during the
adjustment shims assembly:
Illustration 156
Always use suitable extractors to remove the bearings.
Split pins
split pins assembly:
Illustration 154
• Use appropriate adjusting shims and measure

each one separately.
• Complete group measurement or stampings on

the shims are not always reliable: check.
Bearings
bearings assembly:
• Before reassembling the bearings, clean, check

and lubricate them.
Illustration 157
• Before assembling elastic pins, make sure that

the notch is oriented towards the stressing force.
• Spiral elastic pins do not need orientation.
Adhesive and sealant

• Respect the following recommendations during
the adhesive and sealant applications.
Illustration 155 • Use adhesive and sealant as advised by
manufacturer specifications.
• Its advisable to heat up bearings to 80-90 °C
before assembling them onto their respective • Do not use adhesive or sealant where similar
shafts or to cool them (dry ice) before inserting products has been applied previously; totally
them into corresponding bore. remove the old product before applying the new
one.
47
Power Train
Checks
axle control operations:
• Check all grooves: assure that they are not worn

out or damaged.
• Replace spoiled parts with original spare parts.
• Before the reassembly, the seals on rotating

shafts must be replaced.
• Examine accurately all bearings, external rings

Illustration 158 which may be still stuck in their position and pivot
pins on which rolls rotate.
• Ensure that parts to be sealed are clean, dry and
completely grease free in the application area.
• Read the predisposed section in this manual to

know the required type of adhesive and sealant
and relative application areas.
Oil drain
Before carry out the disassembly operations, the oil
must be drained out.
Note: Refer “Operation and Maintenance Manual” for
correct procedure.
Illustration 159
Disposal of used oil must be done according to • Replace those which are worn out or damaged.
laws.
Cleaning
axle cleaning operations:
• Wash all moving parts accurately with diesel fuel

or kerosene.
• Gasoline and watery alkaline solutions are

forbidden.
• Do not wash with steam or hot water, as it will be

very difficult to eliminate surface humidity. Illustration 160
• Dry all parts with a rag or air jet to avoid scratching • Gears should not be spoiled and teething should
from abrasive residuals. not be excessively worn out. Teeth smoothing
should not be deteriorated.
• After the cleaning operations, all the surfaces
should be covered with lubricant so as to protect
it from future oxidation.
48
Power Train
Ends of flanges and special tools

Be careful when hammering special tool or flange
ends, in order to avoid jeopardizing functionality and
integrity of either the tools or the components on which
you are operating.
Lubricant use
In order to lubricate the axles correctly and to reach
the exact operation temperature, it is important to use
the recommended lubricants, keeping their level
constant.
Note : Refer “ Operation and Maintenance Manual”

for lubrication details.
49
Power Train
Rear Axle Disassembly and Assembly Procedure

Assembly
S/N: JRC02961-UP
Flange Group - Disassembly

and Assembly
Some of the following pictures may not show exactly
your axle, but the indicated operations are correct.
Illustration 162
1. Insert the Seal ring (3) into the central body with
a special tool 81808301 and a hammer.
2. Insert the washer (5) on the pinion end and a

new O-Ring (4).
3. Assemble the yoke (2) to the pinion end.
4. Lock the whole with a lock ring (1).
Illustration 161
1. Remove the lock ring (1) and remove the

yoke (2)
2. Collect the O-ring (4) and washer (5)
3. Remove the seal ring (3).
Note : This is a destructive operation for the seal ring.

50
Power Train
Epicyclic Reduction Gear

Group – Disassembly and
Assembly
Illustration 163
1. Unscrew the plug (1) and drain the oil completely 6. To replace the planetary gears (6):
from the epicyclic reduction gear.
• Remove the fastening bolts (8) of every
2. Unscrew and remove both fastening screws (3) planetary gear (6).
of the planetary carrier (2).
• Remove the washers (7).
3. Remove the planetary carrier (2) from the wheel
hub (11) and remove the relative O-Ring (9). • Remove the planetary gears (6) from the pins.
Note: Destructive operation for the O-Ring (9); the • Collect the needles (5) and check their
O-Ring must be replaced. conditions.
4. Position the planetary carrier (2) on a workbench • Collect the thrust washer (4).
and check its wear conditions.
5. Remove the short half-shaft (10) from the wheel

hub (11).
51
Power Train
Assembly Procedure
Illustration 164
Illustration 166
6. Assemble the short half-shaft (10) to the epicyclic

reduction gear (2).
Illustration 165
1. Position the planetary carrier (2) on a workbench.

Insert the thrust washer (4) on every pin.
2. Insert the needles (5) into the planetary gears (6).
Note: Grease well the needle bearings (5). Illustration 167
3. Insert the gears (6) with assembled needles on

7. Assemble a new lubricated O-Ring (9) on the
each pin.
wheel hub (11).
4. Fit the thrust washers (7) to the planetary carrier
pins.
5. Assemble the fastening bolts (8), then

tighten them to the prescribed torque to
67 to 83 N.m (49 to 61 lb ft).
Note : Apply Loctite 270 on the threads before

reassemble the bolt (8).
52
Power Train
8. Align the epicyclic reduction gear group to the 11. Top up the specified oil into the epicyclic reduction
wheel hub (11) using an appropriate lifting device. gear.
Danger: observe all current safety regulations to Note: Refer “Operation and Maintenance Manual” for
guarantee operator’s safety. correct procedure.
12. Fit the plug (1) on the epicyclic reduction gear (2)
and tighten to the prescribed torque to
39 to 63 N.m (29 to 47 lb ft).
Illustration 169
9. Fit the epicyclic reduction gear group to the wheel

hub (11).
10. Assemble the fastening screws (3) and

13 to 26 N.m (10 to 19 lb ft).
53
Power Train
Wheel Hub Group –

Illustration 171
1. Remove the epicyclic reduction gear group before 8. Remove the steel lock ring (6) from the epicyclic
disassembling the wheel hub group. ring gear (4).
2. Slide the half-shaft from the axle beam trumpet. 9. Check the wear conditions of the components.
3. Unscrew and remove the fastening bolts (1) from 10. Remove the wheel hub (8) using levers and a
the wheel carrier (4). hammer to facilitate the operation.
4. Remove the washer (2). Note: collect the bearing cone (7).
5. To remove the wheel carrier (4), screw two of the Note: collect the bearing cone (9)
just removed bolts (1) in the threaded holes.
11. Position the wheel hub (8) on a flat surface and
6. Remove the wheel carrier (4) and the ring remove the seal ring (10) with a lever.
gear (5).
Note: this is a destructive operation for the seal
7. Remove the wheel carrier (4) and the ring ring (10).
gear (5).
54
Power Train
12. Remove the bearing cups (9) and (7), on both 3. The special operation “Set Right” of the bearings
sides of the wheel hub (8), using a hammer and (7) and (9) does not require preload or backlash
a suitable drift. adjustment. Anyway, before assembling new
components check the indicated dimensions.
13. Remove the bearing cone (9) from the axle bean
trumpet end, using a suitable extractor. A= 17.950 ÷ 18.000 mm
B= 64.335 ÷ 64.385 mm
Assembly Procedure C= 23.072 ÷ 23.173 mm
Assemble the wheel hub group before assembling

wheel hub group.
Illustration 174
4. Assemble the bearing cone (9) on the axle bean

trumpet end.
Illustration 172 5. Assemble the wheel hub (8) on the axle and fit
the bearing cone (7) in position.
1. Force both bearing cups (7) and (9) to their wheel
hub (8) housings, using the special tool 81807812
under a press or with a hammer.
2. Insert the seal ring (10) into the wheel hub (8)
with the special tool 81807808 and a hammer.
Illustration 175
Illustration 173
6. Preassemble the wheel carrier (4) and the
epicyclic ring gear (5) with the locking ring (6).
55
Power Train
Illustration 176
Illustration 178
7. If necessary, position the wheel carrier (5) on a 9. Assemble the wheel carrier group on the wheel
workbench and force the bushes (3) to the carrier hub (8) using the two projecting bushes (3) as
surface level with the special tool 81808292. dowel pins and screw the relative bolts (1) in order
to put in contact the wheel carrier (5) with the
Note: the bushes must be assembled with the shown
wheel hub (8).
orientation(notch downward); do not overturn the
bushes.
Illustration 179
Illustration 177
10. Force all the hub dowel bushes (3) completely
8. Force the bushes (3) with the special tool with the special tool 81808292 and a hammer.
81808292. At least two bushes (3) (diametrically-
opposed) must be set slightly higher than the
carrier surface level to be used as dowel pins.
56
Power Train
Note: assemble the thrust washer (2) with the 4 Note: assemble the thrust washer (2) with the 4
notches outward. notches outward. Assemble the thrust washer (2)
and bolts (1). Screw the fastening bolts (1) and
150 to 242 N.m (111 to 179 lb ft).
12. Insert the half shaft in the axle beam.
Note : Apply Loctite 270 on the threads before

reassemble the bolt (1) and remove the excess Loctite
after assembly.
Illustration 181
11. If bushing remain in axle housing assembled

directly the wheel hub, assemble the wheel carrier
group (4) with a suitable tool.
57
Power Train
Axle Beam Trumpet Group –

Illustration 183
Start By:
a. Remove the wheel hub group before

disassembling the axle beam trumpet group.
Refer to Disassembly and Assembly, “Wheel Hub
Group – Disassemble” for the correct procedure.
1. Remove the seal ring (9) from the beam

trumpet (6) with a lever.
Note: Destructive operation for the seal ring.

58
Power Train
Illustration 186
4. Remove the beam trumpet (6) and collect the

Illustration 184 O-Ring (5).
2. Put alignment marks on the beam trumpets, on

the brake cylinders and on the central body, in
order to be absolutely sure to identify the coupled
Once the beam trumpet has been removed, the
parts.
long half shaft (2) is free.
5. Remove the bush (8) from the beam trumpet (6)

only if the wear conditions require this.
Position the axle on supports fitted to hold either
the central body and the two beam trumpets, even
after their disjunction, or secure the disjointed
groups to a lifting device with ropes or belts.
Be careful not to damage the bush seat.
Illustration 185
3. Unscrew and remove the fastening screws (7).
Illustration 187
6. Remove the shaft (2) and the splined sleeve (4).
7. Only if necessary remove the snap ring (3) from

the splined sleeve.
59
Power Train
Assembly Procedure 4. Assemble on the beam trumpet (6) the bush (8)
with the special tool 81808299 and a hammer.
Start By: 5. Assemble a new O-Ring (5) into the beam

trumpet.
a. Assemble the brake group before assembling the
axle beam trumpets group. Refer to Disassembly
and assembly, “Brake Group – Assemble” for the
correct procedure.
Illustration 190
6. Assemble the beam trumpet on the central

body (1) using the reference marks carried out
during disassembly.
Illustration 188
1. Check that the snap ring (3) is already assembled

on the splined sleeve (4). Support the groups properly as already pointed
out for disassembly phase.
2. Assemble the splined sleeve (4) to the shaft (2).
3. Insert the shaft on the central body (1).
Illustration 191
7. Screw in the fastening bolts (7) to the requested

torque to 111 to 137 N.m (82 to 101 lb ft.).
Illustration 189
60
Power Train
Illustration 192
8. Tighten the fastening screws (7) according to the

sequence shown in figure.
Illustration 193
9. Assemble a new seal ring (9) in the beam

trumpet (6) using the special tool 81808300 and
a hammer.
End By:
a. Assemble the Wheel Hub Group. Refer to

Disassembly and assembly, “Wheel Hub Group
– Assemble” for the correct procedure.
61
Power Train
Brake Group – Disassembly

and Assembly
Illustration 194
Illustration 195
1. Remove the beam trumpet and half-shaft from
the brake flange (1).
62
Power Train
2. Remove the components from the brake 4 . Unscrew the fastening screws and remove all the
flange and brake counter plates (7) and brake parts of the self adjust kit (5) and brake
plates (8), brake disc carrier gear (9), brake mechanism return kit (6).
plate (10) and brake counter plate (11).
Note: Remember the position of the brake disc carrier,

it must be reassembled in the same position.
Illustration 199
5. Remove the brake piston (4).

Illustration 197
Note: If necessary, blow in air through the brake oil
3. Remove the brake control group. Refer to Brake input hole to eject the piston, using the minimum
Disassembly and Assembly, “ Brake Control pressure.
Group – Disassemble”.
Danger: Possible swift ejection of the piston.
63
Power Train
Note: The bushes must be aligned with the piston

supporting inner surface.
Illustration 200
6. Remove the O-Rings (2) and (3) from the brake

piston (4). Illustration 203
2. Assemble a new O-Rings (2) and (3) to the brake

Assembly Procedure piston (4). Lubricate the O-Rings.
Illustration 201
Illustration 204
1. Collect the brake piston (4) with special tool
81807813 and a hammer, push the bushes into 3. Insert the piston (4) into the brake cylinder (1)
the self-adjust housings till they are aligned with and position the special tool 81808293 on
the piston supporting inner surface. the piston.
Note: Position the brake piston (4) with a slot aligned

with the hydraulic connection or with the inspection
hole on the brake cylinder (5).
Do not damage the O-rings.
4. With a lever anchored to an eyebolt, exert a

pressure just enough to insert the piston into the
brake flange.
Illustration 202
64
Power Train
5. Insert the large spring, the small spring and the 8. Screw the fastening screws of both kits and
bush of the brake mechanism return kit (6) in the tighten them to the prescribed torque 7 to 11 N.m
largest hole of the brake piston. (5 to 8 Lb ft.).
6. Assemble the spring cover and the screw of the 9. The brake piston must be pushed in the original
brake mechanism return kit (6). position if worn brake discs are replaced by new
discs.
10. Remove straight threads, bleeds or plugs from

the service brake oil port.
Danger: Risk of oil ejection from the axle.
Illustration 207
7. Assemble the bush, the washer and the screw of

the self-adjust kit (5).
65
Power Train
Illustration 212
13. Check that the brake plate (8 and 11) and the
Illustration 210
brake drive plate (7 and 10) do not present any
11. Push the brake piston (4) at the end of stroke sign of burning; on the contrary, replace them.
using the special pad 81808303 and the handle
81807807 with a hammer. 14. Furthermore check brake plate wear and if
necessary replace it.
Note: If new brake plate are installed, before

Position the pad with accuracy, do not damage assembling they should be dipped in the prescribed
the brake piston. oil.
Illustration 213
Illustration 211 15. Reassemble all the components of the brake

group as is shown in figure: brake counter
12. Assemble the brake control group. Refer to Brake plate (7), brake plate (8), brake disc carrier (9),
Disassembly and Assembly, “ Brake Control brake counter plates (10) and brake plates (11).
Group – Assemble”.
Place the brake disc carrier (9) as shown in the

next figure, assemble brake discs with holes
aligned.
66
Power Train
Illustration 214
This is the correct position of the teeth on the

external surfaces of the brake disc carrier (9).
Illustration 215
16. Reassemble the beam trumpet and half-shaft.

67
Power Train
Brake Control Group –

Illustration 216
68
Power Train
Illustration 219
Illustration 217
3. Unloose the locknut (17) and remove the adjusting
screw (16).
Illustration 218
Illustration 220
1. Before disassemble the brake control group
4. Unscrew and remove the fastening screw (1).
Remove the beam trumpet and half shaft. Refer
Disassembly and Assembly, “Axle Beam Group –
Disassembly” for the correct procedure.
2. Remove brake counter plates, brake plates and

brake disc carrier from the brake flange (11). Refer
Disassembly and Assembly, “Brake Group –
Disassembly” for the correct procedure.
Illustration 221
5. Remove the washer (2).

69
Power Train
6. Put an alignment mark on the lever (3) and 9. Remove the spring (4).
shaft (8) for use during installation and to
distinguish between right and left control (for
example: you can put two marks on the right and
only one on the left).
Illustration 226
10. Remove the washer (5) and the spacer (6).

Illustration 223
7. Loosen the lever (3) to release the tension on the

spring (4).
Illustration 227
11. Remove the bracket (20) fastening screws (18)

Illustration 224 and (19).
8. Remove the lever (3).

70
Power Train
12. Remove the bracket (20). 16. Unscrew the shaft screw (14), being careful the
steel ball (13) does not get lost.
Illustration 229
13. Make an alignment mark on the cam (10) near Illustration 232
the screw (9) align with the top of the roll pin, for
use during assembly. 17. Collect the steel ball (13).
14. As already done for the control lever, distinguish

between right operation side and left one.
Illustration 233
Illustration 230 18. Remove the O-Ring (7).
15. Free the cam (10) unscrewing the screw (9).

71
Power Train
19. Remove the shaft (8) and collect the cam (10). 3. Align the reference mark previously done with the
screw (9) hole.
Assembly Procedure
Illustration 237
Illustration 235
4. Assemble a new screw (9) to the shaft (8).
1. Assemble the brake piston. Note: If you remove the screw (9) apply the sealant
(Loctite 542 / Superbond 321) on the thread before
2. Assemble the cam (10) and shaft (8), relative to
reassemble it.
the side you are operating, to the brake
flange (11).
Refering to the marks previously done to identify

the parts on the right side and on the left side.
Illustration 238
5. Tighten the screw (9) to the requested torque

9 to 11 N.m (7 to 8 lb ft.).
72
Power Train
6. Insert the steel ball (13) and the relative 10. Position the supporting bracket (20).
screw (14).
11. Assemble the fastening screws (18) and (19).
Illustration 240
7. Put on thread of the screw (14) a slight layer of Illustration 243

prescribed sealant. 12. Tighten the bracket fastening screws (18)
and (19) to the requested torque to
8. Assemble the screw (14) to the requested torque 30 to 37 N.m (22 to 27 lb ft).
13 to 26 N.m (10 to 19 lb ft).
Illustration 244
Illustration 241
13. Insert the spacer (6), washer (5) and spring (4)
9. Insert a new O-ring (7) on the shaft. on the shaft (8) end.
73
Power Train
Illustration 247
Illustration 245 15. Assemble the brake discs and counter discs, the
half-shaft and beam trumpet.
14. Insert the brake control lever (3), respecting the
reference marks put during disassembly.
Note: It is very important to respect the reference

marks. Control brake assembly could be completed
only after the assembly of brake group and of axle.
Illustration 248
16. Set the brake group, putting the system for 3 times
under pressure of 35 bar for 2 seconds. It is
advisable to use compressed air at high pressure
blown through the breather.
Illustration 246
The braking system (piston, discs and self-adjust)

should be set, before moving the brake control
During group handling and assembling phases, levers.
be careful not to move the brake control lever. This
could cause the uncorrect positioning of the discs • Operate the control levers, setting them on
and of the self adjust groups with the consequent braking position (locked levers).
reduction of brake efficiency.
Note: the lever return springs should not be inserted.
Note: Align the holes on the friction discs; such • Measure the distance between the middle of the
alignment is necessary to grant the correct oil flow connection holes at the ends of the control levers
inside the brake group. and check that it is within the foreseen range: 344
÷ 355 mm
• If the value is not within the foreseen range,

correct the lever position: take them out of the
shaft and reinsert them shifted of one spline so
that the error can be compensated.
74
Power Train
• Repeat the checking operation and the further 19. Hitch the return spring (1) to the brake control
adjustment till the requested conditions are lever (3). Repeat all the described operations also
reached. for the other brake group.
Illustration 249
17. Release the brake control levers (3), assemble Illustration 252
the fastening screws (1) and the relative
20. Check that, in rest position (load of 5 daN), the
washers (2).
measure between the middle of the connection
holes at the lever ends is higher than the minimum
value 344 mm of the requested range.
Illustration 250
18. Tighten the fastening bolt (1) to the requested

torque to 30 to 37 N.m (22 to 27 lb ft). Illustration 253
21. Assemble the nuts (17) on the adjusting

screws (16).
22. Assemble the adjusting screws (16) on the

brackets (20) and screw in them, till they are in
contact with the levers (3).
Illustration 251
75
Power Train
Illustration 254
23. Screw in the two screws of the same measure to

be within the foreseen range for the levers in rest
position: 358 ÷ 369 mm (about 3 mm between
lever and bracket will remain).
Illustration 255
24. If the screw is not perpendicular to the side surface

of the lever, adjust its position by moving the
supporting bracket (20).
76
Power Train
Differential Support Group -

Illustration 256
Illustration 257
1. Remove the brake discs and counter discs.

77
Power Train
Illustration 260
Illustration 258
6. Remove differential housing (6).
2. Secure the brake cylinder (9) to a hoist with
ropes or safety belts.
3. Remove the fastening screw (13).
Illustration 261
7. Remove the O-Ring (5) from the central body (1).

Illustration 259
8. Extract the pipe (3) from the central body (1).
4. Remove the brake cylinder.
9. Remove the O-Rings (2) and (4) from the
pipe (3).
The differential box is free.
5. Remove the O-Ring (8) from the brake

cylinder (9).
78
Power Train
12. Use a driver and a hammer to remove the bearing

cup (7) from the brake cylinder (9).
Do not invert the bearing cups if the bearings are

not replaced.
Assembly Procedure
Illustration 262
10. Unscrew and remove the screw (12) and the ring
nut retainer (11) from the brake cylinder (9).
Illustration 265
1. Assemble the pinion group before assemble the

differential support group. Refer to Disassembly
and Assembly, “Pinion Group – Assembly” for the
correct procedure.
Illustration 263
11. Unscrew and remove the adjuster ring nut (10)

from the brake cylinder (9) with the tool 81808297.
Illustration 266
Illustration 264
79
Power Train
2. Lubricate and assemble new O-Rings (2) and (4)

on the pipe (3).
3. Insert the pipe (3) into the central body (1).
4. Lubricate and assemble new O-Ring (5) on every

side of the central body (1).
Illustration 269
7. Assemble a new well lubricated O-Ring (8) on the

brake cylinder (9) housing.
8. First assemble the right brake cylinder (RH) to

the central body (1).
Illustration 267
9. Insert the differential group into the central
5. Position the brake cylinder (9) on a flat surface body (1).
and force the bearing cup (7) using the special
tool 81807816.
The bevel gear must be placed on the left side (LH).
Do not invert the bearing cups if the bearings are 10. Assemble the left brake cylinder (LH).
not replaced.
Note: Check that the reference marks made during
the disassembly between the brake cylinders and the
central body coincide.
Illustration 268
6. Measure the external diameter C of the bevel

crown gear assembled to differential housing.
Illustration 270
Calculate the value: R=C/2 mm
Note: this value is necessary to measure the backlash 11. Assemble the fastening screws (13).
between pinion and crown.
80
Power Train
12. Tighten the fastening screws to the requested

torque 51 to 83 N.m (38 to 61 lb ft)
13. Assemble in the shown position a fastening

screws M14 x 120 mm to torque of 79 N.m
(58 lb ft) on both sides.
Illustration 273
17. Move the bracket of the tool 81807826 installed

on the differential housing hole alternately by
hand.
18. Measure the backlash between pinion and crown.
Illustration 271
19. Check if the measured backlash value is within
the prescribed range: 0.15÷0.30 mm
14. Screw both adjuster ring nuts (10) using the tool
81808297 till the backlash is eliminated and the 20. Set the backlash by turning the adjusting ring
differential bearings are slightly loaded. nuts (10) using the wrench 81808297.
A A
B B
Illustration 272
Illustration 274
15. Assemble the special tool 81807826 on the
differential housing hole. 21. Adjust the ring nuts (10), remembering that:
16. Position a comparator with the feeler in contact • If the measured backlash is less than the given
with and at 90° respect to the surface of the special tolerance range, screw the ring nut from the side
tool bracket, in correspondence with the reference opposite to the ring gear and unscrew the opposite
R value. one of the same measure (A);
• If the measured backlash is greater than the

given tolerance range, screw the ring nut from
the side of the ring gear and unscrew the opposite
one of the same measure (B).
81
Power Train
Illustration 277
Illustration 275
26. The total preloading Tm is measured on the special
22. Once the adjustment of the pinion-bevel gear tool 81808302 (gauge diameter Dm= 104.4 mm).
backlash has been carried out, check also that
there is a minimum preloading on the differential 27. The measured value should be within the following
housing bearings. range: Tm= (Pm+11.1) ÷ (Pm+16.7) N
23. Repeat the whole sequence of the above Where Pm is the effectively preloading measured
mentioned operations till the indicated conditions on the special tool 81808302 (gauge diameter
are reached. Dm= 104.4 mm).
A A
B B
Illustration 278
Illustration 276
28. If the measurement is not within the requested
24. Once the pinion-ring gear backlash has been range, check well the assembly of each
established, measure the total preloading T of the component and operate on the adjuster ring
bearings (pinion-crown bevel gear system) nuts (10) of the differential support:
25. Use a dynamometer whose cord is wound on the • If the total preloading is less than the given
special tool 81808302 inserted on the end of range, screw in both adjuster ring nuts by the same
pinion shaft. measure, keeping the pinion-ring gear backlash
value unchanged (A);
• If the total preloading is greater than the given

All the preloads should be measured without the range, unscrew both adjuster ring nuts by the
seal rings. same measure, keeping the pinion-ring gear
backlash value unchanged (B).
82
Power Train
Illustration 279
29. Once all the adjustment operations have

been completed, fit the adjuster ring nut
retainers (11) and their respective screws (12),
tightening them to the prescribed torque to
6.5 to 13.7 N.m (4.8 to 10 lb ft)
Turn the adjuster ring nuts (10) slightly in order to

allow the assembly.
30. Remove the fastening screws M14 x 120 mm on

both sides. See previous step (13).
83
Power Train
Differential Group -
Illustration 280
This will make both differential half boxes (4)

and (12) free, so take care not to drop the internal
components.
Illustration 281
1. Lock the differential with a clamp.
2. Unscrew the fastening bolts (1) and remove the

bevel gear crown (2).
84
Power Train
Assembly Procedure
Illustration 282
2. Make alignment marks on the two half boxes

before split them.
3. Disassemble the differential box in two half Illustration 284

boxes (4) and (12) complete with the relative
components. 1. Assemble the bearing cones (3) and (13) on the
half housings (4) and (12), using the special tool
4. Disassemble all the components. Check the 81807811 and a hammer.
operating and wear conditions of the components.
Illustration 285
2. Position a half housing (4) or (12) on a workbench

and assemble all inner components: thrust
Illustration 283 washers (5) and (11), sun gears (6) and (10),
spiders (9), spider gears (10), thrust washers (9),
5. Remove the bearings cones (3) and (13) of the as shown in figure. Join the two half boxes,
half boxes (4) and (12), using two levers or a three- aligning the reference marks made during
hold extractor. disassembly.
85
Power Train
Illustration 286
Note: clean with care the matching surfaces between

bevel gear and differential housing.
3. Spread a film of sealant Loctite 638 / Superbond

433 on the contact surface between bevel gear
and differential housing.
4. Position the bevel crown gear (2) on the half

box (4).
5. Apply the Loctite 270 on the thread and tighten

the screws (1) to the prescribed torque to
155 ± 8 N.m (144 ± 6 lb ft).
86
Power Train
Pinion Group Disassembly and

Assembly
Illustration 287
1. Unscrew the lock nut (10) using special tools 2. Tap the end shaft with a soft hammer to remove
81808289 and 81808291 the bevel pinion (1). Collect the washer (9) and
the bearing cone (8).
Note: This operation damage the ring nut; the ring
nut (10) must be replaced when assembling the group.
87
Power Train
Illustration 290
3. Once the bevel pinion (1) has been removed, Illustration 292
collect the washer (6), the collapsible spacer (5)
and the washer (4). 6. Remove the bearing cone (3) of the bevel
pinion (1) with a standard extractor.
Note: the collapsible spacer (5) must be replaced
when assembling the group. 7. Collect the shim (2).
Assembly Procedure
Illustration 291
4. Check the bearing cups wear condition. Illustration 293
5. If bearings replacement is necessary, remove

bearing cups (3) and (8) from central body with a 1. Position the central body (7) on a workbench.
drift and a hammer.
2. Fit the bearing cups (3) and (8) into their seats
using the special tools kit 81808298.
88
Power Train
Illustration 294
Illustration 296
3. Use the special tools false pinion 81808294 and

false differential box 81808290 to measure the 8. Insert the false differential box 81808290 into the
conic distance. central body (7).
4. Insert into the seats the bearing cups (3) and (8) 9. Check that the false differential box is inserted in
and the false pinion. both differential support housings.
5. Tighten the ring nut (10) to eliminate the backlash.
Illustration 297
Illustration 295 10. To adjust bevel gear/pinion measure the distance

“A” with a depth gauge.
6. Check the correct positioning of the right and left
brake cylinder and differential housing supports, Calculate the value “X” as follows: X=(A+C)-B mm
using the reference marks on them and on the
where “B” and “C” are known.
central body (7).
7. Assemble the two brake cylinders with their

fastening bolts.
89
Power Train
Illustration 298
Illustration 300
11. From the value “X” deduct the value “V” (stamped
on the pinion head) to get the value “S”. 13. Loosen and remove the ring nut (10).
S=X-V mm 14. Remove the false pinion 81808294 and the

bearing cones (3) and (8) from the central
body (7).
15. Disassemble the false differential box 81808290

from the brake cylinders and then unscrew the
screws to remove the brake cylinders.
Illustration 299
Table 17
SHIMS RANGE
Thick. -
2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4
mm
Quantity --- --- --- --- --- --- --- --- --- --- Illustration 301
12. Choose the shim (2) with thickness value (S) 16. Once you have chosen the suitable shim (2), insert
among the available shims range. it on the pinion shaft with the chamfer against the
pinion head, as shown in figure.
90
Power Train
Illustration 302
Illustration 304
17. Insert the chosen shim (2) with the chamfer

against the gear on the pinion shaft (1). 20. Insert the bevel pinion (1) unit into the central
body (7) and the bearing (8) into the pinion shaft,
18. Force the bearing (3) on the pinion shaft (1) with as shown in figure.
the special tool 81808295 under a press, making
sure that it is well set. 21. Force the bearing (8) in position with the special
tool 81808295 and a hammer.
19. Assemble the shim (4), a new collapsible
spacer (5) and the shim (6) to the pinion shaft. Note: push the pinion against the central body to
perform this operation.
Note: Use always a new collapsible spacer (5).
Illustration 305
Illustration 303 22. Insert the ring nut washer (9) and screw a new
lock ring nut (10) on the pinion end.
Note: Check the right assembly sequence.
23. Screw the ring nut (10) in, using the wrench for
ring nut 81808289 and for pinion retainer
81808291.
The torque setting is given by the preloading

measurement on bearings (3) and (8), tighten the
ring nut (10) gradually.
91
Power Train
Note: If the tightening is excessive, the collapsible

spacer (5) must be replaced and the procedure
repeated.
24. When you check the preloading, it is advisable to

beat slightly both pinion ends (1) with a soft
hammer, so as to help setting the bearings (3)
and (8).
Illustration 308
28. Once the requested preloading value is achieved,

stake the ring nut (10), using a hammer and a
chisel.
29. Before to assemble the seal pinion assemble the

differential.
Illustration 306
25. To measure the preloading P of the pinion taper

roller bearings, use a dynamometer whose cord
is wound on the special tool 81808302 inserted
on the end of pinion shaft.
26. The adjustment is carried out by increasing the

ring nut torque gradually, being careful not to
exceed.
Illustration 309
30. Assemble the flange group.
Illustration 307
27. The effectively preloading Pm is measured on the

special tool 81808302 (gauge diameter
Dm= 104.4 mm)
The measured value should be within the following

range: Pm= 30.7÷45.7 N
92
Power Train
Testing After Assembly

Testing Methods
1. With engine off, lift the axle so that the tyres get
away from the ground.
2. Engage the gear so that the pinion gets locked.
3. With the help of another person standing on the

opposite side, begin the assembly testing by
rotating as much as possible both the wheels
forward. (Both the wheels should get blocked after
a while.)
4. Keeping the pinion locked, free the right wheel

and rotate the left one in the line of march. Rotate
the right wheels in the opposite direction.
The wheel will move freely without difficulty and

the right wheel will move in the opposite direction
if the assembly has been carried out correctly.
Repeat the same operation in the opposite direction

(reverse gear).
IF ONE WHEEL DOES NOT ROTATE FREELY IN

BOTH DIRECTIONS, then check step by step all
assembly operations.
Check and see that the brakes are regulated correctly

and functioning properly.
93
Power Train
Special Tools (Rear Axle) 81808290

False Differential Box
S/N: JRC02961-UP
The special drifts/pad used to assembly the seals,

bearings and bushes should always be used with the
interchangeable handle 81807807; its use is
recommended together with a suitable safety handle
in order to protect the hands.
81807807
Handle
Illustration 313
81807816
Driver
Illustration 310
81808289
Wrench
Illustration 314
81807811
Handle
Illustration 311
81807808
Driver
Illustration 315
Illustration 312
94
Power Train
81808291 81807813
Wrench Driver
81807812 81808293
Driver Driver
81808292 81808294
Driver False Pinion

95
Power Train
81808295 81808298
Driver Bearing Insertion Kit
81808296 81808299
Driver Driver
81808297 81807826
Wrench Measurement Tool

96
Power Train
81808300 Tyre and Rim (Front) – Remove

Driver
and Install
SMCS Code: 4202-010-FR
S/N : JRC02961-UP
Removal Procedure
1. Raise the machine with the bucket. Place wood
Illustration 328
81808301
Driver
Illustration 331
2. Remove the nuts (1) in order to remove the tyre

and rim.
Illustration 329 3. Remove the tyre and rim.
81808302 1. Install the tyre and rim.
Measurement Tool
Illustration 330
81808303
Illustration 332
Pad
2. Install the nuts (1). Tighten nuts to a torque of
400 ± 40 N.m (295 ± 30 lb ft).
3. Raise the machine with the bucket. Remove the

wood blocks under the front axle.
97
Power Train
Tyre and Rim (Rear) – Remove Installation Procedure

and Install
SMCS Code: 4202-010-RE
S/N : JRC02961-UP
Removal Procedure
Table 18
Required Tools
A 9U-9745 Jack 1
Illustration 334
B 9U-9759 Jack 2
1. Install tyre and ten nuts. Tighten nuts to a torque

of 400 ± 40 N.m (295 ± 30 lb ft).
2. Position tool (A) and raise the machine.
3. Remove tool (B) and lower the machine.
Illustration 333
1. Position tool (A) suitably and raise the machine.
2. Position tool (B) suitably to rest the machine and

remove tool (A).
3. Attach a suitable lifting device to tyre.
4. Remove ten nuts and tyre.

98
Power Train
Index Section
Index Front Axle - Installation Procedure .................... 30

Front Axle - Removal Procedure ....................... 29
A P
Axle Beam Trumpet Group - Disassembly and Parking Brake - Remove and Install ................. 26
Assembly .......................................................... 57 Removal Procedure ........................................ 26
Disassembly Procedure ................................. 57 Installation Procedure ..................................... 27
Assembly Procedure ...................................... 59 Pinion Group Disassembly and Assembly ........ 86
Disassembly Procedure ................................. 86
Assembly Procedure ...................................... 87
B
R
Brake Control Group - Disassembly and
Assembly .......................................................... 67
Disassembly Procedure ................................. 67 Rear Axle - Disassembly Special
Assembly Procedure ...................................... 71 Recommendations forrepair operations ............ 45
Brake Group - Disassembly and Assembly ...... 61 Rear Axle - Installation Procedure .................... 43
Disassembly Procedure ................................. 61 Rear Axle - Removal Procedure ....................... 42
D S
Differential Group - Disassembly and Solenoid Valve (Transmission) - Assembly
Assembly .......................................................... 83 Procedure ............................................................ 7
Disassembly Procedure ................................. 83 Solenoid Valve (Transmission) - Disassembly
Assembly Procedure ...................................... 84 Procedure ............................................................ 6
Differential Support Group - Disassembly and Solenoid Valve (Transmission) - Installation
Assembly .......................................................... 76 Procedure ............................................................ 8
Disassembly Procedure ................................. 76 Solenoid Valve (Transmission) - Removal
Assembly Procedure ...................................... 78 Procedure ............................................................ 5
Drive Shaft – Remove and Install ..................... 25 Special Tools (Rear Axle) .................................. 93
Installation Procedure ..................................... 25 Steering Cylinder - Assembly Procedure .......... 40
Removal Procedure ........................................ 25 Steering Cylinder - Disassembly Procedure ..... 38
Steering Cylinder - Installation Procedure ........ 41
E Steering Cylinder - Removal Procedure ........... 37
System Pressure - Release Procedure ............... 5
Epicyclic Reduction Gear Group - Disassembly
and Assembly .................................................... 50 T
Assembly Procedure ...................................... 51 Testing After Assembly ...................................... 92
Tie Bar (Steering) - Remove and Install ............ 36
F Removal Procedure ........................................ 36
Installation Procedure ..................................... 37
Transmission (Direct Drive) - Assembly
Flange Group - Disassembly and Assembly ..... 49 Procedure ......................................................... 17
Disassembly Procedure ................................. 49 Transmission (Direct Drive) - Disassembly
Assembly Procedure ...................................... 49 Procedure .......................................................... 11
Front Axle - Assembly ....................................... 33 Transmission (Direct Drive) - Installation
Assembly Procedure ...................................... 33 Procedure ......................................................... 23
Front Axle - Disassembly .................................. 31 Transmission (Direct Drive) - Removal
Disassembly Procedure ................................. 31 Procedure ............................................................ 9
99
Power Train
Index Section
Tyre and Rim (Front) – Remove and Install ...... 96

Removal Procedure ........................................ 96
Tyre and Rim (Rear) – Remove and Install ...... 97
Removal Procedure ........................................ 97
Wheel Hub Group - Disassembly and

Assembly .......................................................... 53
100
Power Train
Index Section
101
Power Train
Index Section
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All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.

424B Disassembly and Assembly (Transmission) (RESM3578-02)

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424B Disassembly and Assembly (Transmission) (RESM3578-02)

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RESM3578-03

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Accidental machine starting can cause injury or

To avoid accidental machine starting, turn the

Place a do not operate tag at the battery discon-

Disassembly and Assembly Solenoid Valve (Transmission)

System Pressure - Release Removal Procedure for Direct Drive

Hydraulic oil pressure can remain in the hydraulic

5. Slowly loosen the filler cap in order to release

6. Tighten the filler cap.

7. The pressure in the hydraulic system has

a. Remove the transmission solenoid valve. Refer

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

Note: Cleanliness is an important factor. Before

4. Remove transmission solenoid valve (4).

1. Remove nut (1).

5. Check the four O-rings (5) for wear. Replace the

Note: O-rings, gaskets, and seals should always be

2. Remove cover (2), O-ring seal (3), solenoid (4),

3. Repeat Steps 1 and 2 for the opposite side of Illustration 6

Solenoid Valve (Transmission)

Installation Procedure for Direct

Personal injury can result from hydraulic oil pressure

Hydraulic oil pressure can remain in the hydraulic

Dispose of all fluids according to local regulations and

5. Install the floorplate (1).

Transmission (Direct Drive) -

a. Remove the rear drive shaft. Refer to Disassembly

5. Remove plug (4) and drain the transmission oil

2. Place tooling (A) under rear frame (1).

6. Remove four bolts (5).

7. Repeat Step 6 for the opposite side.

8. Remove two bolts (6).

11. Support transmission (10) with tooling (C), as

12. Attach tooling (D) to tooling (C) and transmission

Illustration 17 13. Remove twelve bolts (11).

Transmission (Direct Drive) - Note: Cleanliness is an important factor. Before

Note: The transmission will be disassembled in

a. Remove the transmission. Refer to Disassembly

Refer to Special Publication, NENG2500, “Caterpillar

Dispose of all fluids according to local regulations and

3. Remove plug (3). Drain the transmission oil

2. Use tooling (C) in order to remove bearing cone

(Direct Drive) Output Shaft (Front)

4. Remove two roller bearings (13), spacer (14),

1. Remove front output shaft (9).

(Direct Drive) Output Shaft (Rear)

7. Remove snap ring (20), retainer (21), and spring Illustration 35

2. Remove plug (25). 5. Remove bearings (33), spacer (34), and

2. Use tooling (G) in order to remove bearings (45)

(Direct Drive) Input Shaft

1. Remove the input shaft by hand for disassembly.

8. Use tooling (E) in order to remove gear (42).

(Direct Drive) Shaft

1. Remove the shaft by hand for disassembly.

2. Use tooling (H) in order to remove bearing (47).

2. Use tooling (G) in order to remove bearings (43)

Illustration 49 9. Remove gear (59) from the clutch pack.

1. Install bearing cups (60), (61), (62), (63), and

Assemble (Direct Drive) Input Shaft

Note: Cleanliness is an important factor. Before

Note: Apply a light film of clean transmission oil to