This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to completely disassemble the transmission, including removing components like the transmission case assembly, shaft assemblies, clutches, seals, gears, and sensors. Detailed illustrations accompany each step. Safety warnings are provided to release pressurized components and springs carefully due to risk of injury from propelled parts. Special tools are required to properly disassemble the transmission.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fujseskemmesd
This document provides disassembly instructions for the transmission of a 120H Motor Grader. It lists over 30 steps to fully disassemble the transmission, including removing components like the transmission control valve, pump, brake, seals, shafts, gears, and bearings. Detailed illustrations accompany each step to show how to position tools and lift components. Safety precautions are provided for steps that involve compressed springs. The transmission contains several heavy components, so lifting devices and assistance from another person are recommended for their removal.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...jjskekfsme
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of components like seals, shafts, gears, plates, sensors and more. Many components need to be removed together or special tools are required due to the components' interconnecting nature and weight. Safety precautions are provided due to stored spring energies in some components. The detailed instructions include illustrations to clearly show each step.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fiskefjskemem
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of various components like shafts, gears, seals, plates and sensors. Special tools are required for tasks like compressing clutches and removing bearings. Safety precautions are provided, as some components can be under spring pressure. The transmission must be carefully disassembled into its individual parts to allow for repair or replacement of worn items.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fusjefjkksemmd
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of components like seals, shafts, gears, plates, sensors and more. Many components need to be removed together or special tools are required due to the components' interconnecting nature and weight. Safety precautions are provided due to stored spring energies in some components. The detailed instructions include illustrations to clearly show each step.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fusjejfksemem
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of components like seals, shafts, gears, plates, sensors and more. Many components need to be removed together or special tools are required due to the components' interconnecting nature and weight. Safety precautions are provided due to stored spring energies in some components. The detailed instructions include illustrations to clearly show each step.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...shanlianjiu7712
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, including removing components like the transmission case assembly, pump, brake, shafts, seals, sensors, and clutches. Detailed illustrations accompany each step to show how to position the transmission and what tools to use. Safety warnings are included for steps involving compressed springs.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...vyqjjl248
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, including removing components like the transmission case assembly, pump, brake, shafts, seals, sensors, and clutches. Detailed illustrations accompany each step to show how to position the transmission and what tools to use. Safety warnings are included for steps involving compressed springs.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...jiduanbu
This document provides instructions for disassembling the transmission of a 120H Motor Grader. It lists the required tools and presents a step-by-step process with illustrations. Key steps include removing the transmission case from the cover assembly, separating the first/third and high/low shaft assemblies, and dismantling individual components such as clutches, seals, and sensors. Proper lifting equipment is required due to the heavy weight of transmission components.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fujseskemmesd
This document provides disassembly instructions for the transmission of a 120H Motor Grader. It lists over 30 steps to fully disassemble the transmission, including removing components like the transmission control valve, pump, brake, seals, shafts, gears, and bearings. Detailed illustrations accompany each step to show how to position tools and lift components. Safety precautions are provided for steps that involve compressed springs. The transmission contains several heavy components, so lifting devices and assistance from another person are recommended for their removal.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...jjskekfsme
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of components like seals, shafts, gears, plates, sensors and more. Many components need to be removed together or special tools are required due to the components' interconnecting nature and weight. Safety precautions are provided due to stored spring energies in some components. The detailed instructions include illustrations to clearly show each step.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fiskefjskemem
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of various components like shafts, gears, seals, plates and sensors. Special tools are required for tasks like compressing clutches and removing bearings. Safety precautions are provided, as some components can be under spring pressure. The transmission must be carefully disassembled into its individual parts to allow for repair or replacement of worn items.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fusjefjkksemmd
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of components like seals, shafts, gears, plates, sensors and more. Many components need to be removed together or special tools are required due to the components' interconnecting nature and weight. Safety precautions are provided due to stored spring energies in some components. The detailed instructions include illustrations to clearly show each step.
Caterpillar cat 120 h motor grader (prefix alz) service repair manual (alz000...fusjejfksemem
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, involving the removal of components like seals, shafts, gears, plates, sensors and more. Many components need to be removed together or special tools are required due to the components' interconnecting nature and weight. Safety precautions are provided due to stored spring energies in some components. The detailed instructions include illustrations to clearly show each step.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...shanlianjiu7712
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, including removing components like the transmission case assembly, pump, brake, shafts, seals, sensors, and clutches. Detailed illustrations accompany each step to show how to position the transmission and what tools to use. Safety warnings are included for steps involving compressed springs.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...vyqjjl248
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, including removing components like the transmission case assembly, pump, brake, shafts, seals, sensors, and clutches. Detailed illustrations accompany each step to show how to position the transmission and what tools to use. Safety warnings are included for steps involving compressed springs.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...jiduanbu
This document provides instructions for disassembling the transmission of a 120H Motor Grader. It lists the required tools and presents a step-by-step process with illustrations. Key steps include removing the transmission case from the cover assembly, separating the first/third and high/low shaft assemblies, and dismantling individual components such as clutches, seals, and sensors. Proper lifting equipment is required due to the heavy weight of transmission components.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...iphg8793466
This document provides instructions for disassembling the transmission of a 120H Motor Grader. It lists the required tools and presents a step-by-step process with illustrations. Key steps include removing the transmission case from the cover assembly using special tools, and then removing individual components like shafts, gears, seals and sensors from each assembly. Safety precautions are noted for steps involving compressed springs. The goal is to fully disassemble the transmission into its core components.
Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...shenjiao97221
This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, including removing components like the transmission case assembly, pump, brake, shafts, seals, sensors, and clutches. Detailed illustrations accompany each step to show how to position the transmission and what tools are required. Safety notices are included to warn of spring pressures during clutch removal.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to allow maintenance and repair of the torque converter while ensuring correct reassembly.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to repair or replace parts of the torque converter freewheel stator.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to allow maintenance and repair of the torque converter while ensuring correct reassembly.
The document provides instructions for disassembling and assembling the freewheel stator of a torque converter. It lists 35 steps for disassembly, including removing bolts, valves, sensors, gears, and other components. It then lists 29 steps for assembly, instructing technicians to clean parts, press components together, and torque bolts to the specified values. The overall procedure involves carefully separating and then reassembling each part of the torque converter.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, bearings, gears, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing certain components. The overall procedure involves precisely reassembling the many intricate internal components of the torque converter housing.
The document provides instructions for disassembling and assembling the freewheel stator of a torque converter. It lists 35 steps for disassembly, including removing bolts, valves, sensors, gears, and other components. It then lists 29 steps for assembly, instructing technicians to clean parts, press components together, and torque bolts to the specified values. The overall procedure involves carefully separating and then reassembling each part of the torque converter.
The document provides instructions for disassembling and assembling the freewheel stator of a torque converter. It lists 35 steps for disassembly, including removing bolts, seals, bearings and other components. It then lists 29 steps for assembly, installing components in reverse order and noting that cleanliness is important. Tools include link brackets, eyebolts and retaining ring pliers. Torque specifications are provided for certain fasteners.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to repair or replace parts of the torque converter freewheel stator.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, seals and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. Cleanliness is emphasized throughout to prevent dirt from entering the internal mechanism.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to repair or replace parts in the torque converter freewheel stator.
This document provides instructions for disassembling and assembling the rear axle of a M318D wheeled excavator. The disassembly procedure involves removing 23 components including the carrier housing, planetary gears, thrust washers, retaining rings, and hub. The assembly procedure describes installing these 23 components in reverse order and adjusting clearance between discs and setting end play between components. Tools required include retaining ring pliers, drivers, spanners, pry bars, pullers, and torque wrenches.
This document provides instructions for disassembling and assembling the piston pump used in the steering system of a 966H wheel loader. It outlines 28 steps for disassembly, removing components like bolts, valves, springs, and pistons. It then outlines 34 steps for assembly, reversing the disassembly process and including checks for proper installation like measuring axial shaft end play. The purpose is to repair or replace internal components while maintaining correct assembly and torque specifications to ensure proper functioning of the steering pump.
The document provides instructions for removing and installing a camshaft on a Caterpillar 3126 engine. It describes removing components like the governor, side covers, and front cover. It instructs turning the crankshaft to top center compression for the number 1 piston and installing a timing bolt in the flywheel for installation timing. The removal procedure has three steps: 1) Turn the crankshaft, 2) Install timing bolt, 3) Remove camshaft. Reinstallation follows the reverse order. Guidelines are provided for determining if parts can be reused.
The document provides instructions for removing and installing various components of the transmission system for a 730C2 Articulated Truck. The first section describes removing the torque converter housing and installing a new housing. The second section explains how to remove and install the relief valve for the torque converter inlet. The third section gives directions for removing and installing the accessory drive component of the transmission.
The document provides instructions for removing and installing various engine components on a Caterpillar C13 engine, including:
- Camshaft - removal involves supporting lifters with a magnetic tool, removing bolts and gears, and carefully removing the camshaft with support. Installation requires proper timing.
- Camshaft gear - removed using a press and installed by heating to 315°C.
- Camshaft bearings - removed using a puller tool and lubricant, installed using a sleeve tool and measured for proper depth.
- Engine oil pan - removed by draining oil, removing fasteners and components, and installed by applying sealant and torquing fasteners in
This document provides instructions for disassembling and assembling the transmission of a 442D backhoe loader. It lists over 30 required tools and gives step-by-step instructions to disassemble each component of the transmission, including removing gears, bearings, shafts, and housing. The assembly section similarly provides instructions to install each component in reverse order.
This document provides instructions for removing and installing the front housing on a Caterpillar 3054 engine. It describes:
1. Removing bolts to separate the front housing from the cylinder block and oil pan.
2. Removing the front housing and gasket.
3. Installing a new gasket, applying sealant, and bolting the front housing back into place. Tightening bolts in a specific sequence is emphasized.
This service repair manual provides instructions for installing an engine in a 430F2 Backhoe Loader. It outlines 17 steps for the installation, which include attaching the engine, connecting components like the bell housing, flywheel, mounts and panels. It also details connecting wiring harnesses, installing additional components and filling fluids before completing the installation. The manual provides diagrams to illustrate each step in the engine installation process.
This document provides instructions for removing and installing the valve mechanism cover on a Caterpillar 430F2 backhoe loader with a C4.4 engine. It outlines the necessary tools and describes a 7 step process for removal and a 9 step process for installation. Safety notices are included to keep parts clean and prevent damage to electronic components when removing and installing the cover.
This document provides instructions for removing and installing a hydraulic tank on a 430F Backhoe Loader. The removal procedure involves disconnecting hoses and clamps connecting the tank to other components, and removing bolts to detach the tank assembly. Components like a strainer and gauge are also removed from the tank. The installation procedure is the reverse of removal.
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Caterpillar Cat 120H Motor Grader (Prefix ALZ) Service Repair Manual (ALZ0000...iphg8793466
This document provides instructions for disassembling the transmission of a 120H Motor Grader. It lists the required tools and presents a step-by-step process with illustrations. Key steps include removing the transmission case from the cover assembly using special tools, and then removing individual components like shafts, gears, seals and sensors from each assembly. Safety precautions are noted for steps involving compressed springs. The goal is to fully disassemble the transmission into its core components.
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This document provides disassembly instructions for the transmission of a 120H motor grader. It lists over 40 steps to fully disassemble the transmission, including removing components like the transmission case assembly, pump, brake, shafts, seals, sensors, and clutches. Detailed illustrations accompany each step to show how to position the transmission and what tools are required. Safety notices are included to warn of spring pressures during clutch removal.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to allow maintenance and repair of the torque converter while ensuring correct reassembly.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to repair or replace parts of the torque converter freewheel stator.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to allow maintenance and repair of the torque converter while ensuring correct reassembly.
The document provides instructions for disassembling and assembling the freewheel stator of a torque converter. It lists 35 steps for disassembly, including removing bolts, valves, sensors, gears, and other components. It then lists 29 steps for assembly, instructing technicians to clean parts, press components together, and torque bolts to the specified values. The overall procedure involves carefully separating and then reassembling each part of the torque converter.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, bearings, gears, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing certain components. The overall procedure involves precisely reassembling the many intricate internal components of the torque converter housing.
The document provides instructions for disassembling and assembling the freewheel stator of a torque converter. It lists 35 steps for disassembly, including removing bolts, valves, sensors, gears, and other components. It then lists 29 steps for assembly, instructing technicians to clean parts, press components together, and torque bolts to the specified values. The overall procedure involves carefully separating and then reassembling each part of the torque converter.
The document provides instructions for disassembling and assembling the freewheel stator of a torque converter. It lists 35 steps for disassembly, including removing bolts, seals, bearings and other components. It then lists 29 steps for assembly, installing components in reverse order and noting that cleanliness is important. Tools include link brackets, eyebolts and retaining ring pliers. Torque specifications are provided for certain fasteners.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to repair or replace parts of the torque converter freewheel stator.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, seals and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. Cleanliness is emphasized throughout to prevent dirt from entering the internal mechanism.
The document provides instructions for disassembling and assembling the freewheel stator component of a 962H wheel loader torque converter. It lists 35 steps for disassembly, including removing bolts, gears, bearings, and other internal parts. For assembly, it lists 29 steps reversing the disassembly process and provides torque specifications for securing components. The purpose is to repair or replace parts in the torque converter freewheel stator.
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Product: MOTOR GRADER
Model: 120H MOTOR GRADER ALZ
Configuration: 120H Motor Grader ALZ00001-UP (MACHINE) POWERED BY 3126B Engine
Disassembly and Assembly
120H and 135H Motor Graders Power Train
Media Number -RENR4160-05 Publication Date -01/04/2005 Date Updated -22/05/2017
i01967370
Transmission - Disassemble
SMCS - 3002-015; 3030-015; 3159-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7575 Link Bracket 3
B 154-6181 Forcing Screw 2
C 6V-5221 Bolt 1
D 4C-8156 Fixture 1
E 6V-3918 Bolt 1
F 4C-8157 Lifting Fixture 2
G 1U-6405 Three Jaw Puller 1
H 1U-6341 Threaded Rod 1
J 5P-7970 Nut 1
K 9U-7479 Compressing Tube 1
L 5B-0637 High Idle Nut 1
5F-7353 Washer 1
1B-4207 Full Nut 2
5F-7369 Puller Leg 2
3H-0465 Push-Puller Plate 2
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3. 5F-7366 Screw 1
5P-4808 Cap 2
1U-9895 Crossblock 1
M
9S-9152 Block 2
1B-4206 Nut 4
8B-7552 Forcing Bolt 2
N 1U-6343 Threaded Rod 1
P 6V-8149 Nut 1
Q 2P-8312 Pliers 1
R
1P-2326 Screw 1
1P-2325 Head 1
3H-0462 Bolt and Nut 4
8H-0709 Strap 4
5F-7373 Jaw 3
T 3E-3882 Eyebolt 1
Start By:
a. Remove the transmission. Refer to Disassembly and Assembly, "Transmission - Remove"
for the correct procedure.
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4. Illustration 1 g00997069
1. Install Tooling (A) on transmission control valve (1). Attach a suitable lifting device to
Tooling (A).
2. Remove bolts (2) and remove transmission control valve (1). The weight of transmission
control valve (1) is approximately 30 kg (65 lb).
3. Remove temperature sensor (3). Remove tube assembly (4). Remove hose assemblies (5).
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5. Illustration 2 g01021534
4. Remove hose assembly (8) and remove intermediate sensors (9) and (6).
5. Attach a suitable lifting device to pump (11). Remove bolts (10). Remove pump (11). The
weight of pump (11) is approximately 25 kg (55 lb).
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6. Illustration 3 g00997084
6. Remove bolt (12) and yoke (13). Remove bolts (14) and brake (15). Use two people to
remove brake (15). The weight of brake (15) is approximately 34 kg (75 lb).
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7. Illustration 4 g00997086
7. Remove O-ring seal (14A).
Illustration 5 g00997489
8. Remove plates (15A), disc (15B), hub (15C), and dowels (15D).
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9. Illustration 7 g00997091
10. Remove input sensor (18). Remove bolts (20A). Remove plate assembly (20) and harness
assembly (19).
Illustration 8 g00997251
11. Place transmission (21) level on the floor.
12. Remove bolts (22) , the four covers, and the O-ring seals from transmission case assembly
(23).
13. Remove bolts (24) from the transmission case assembly (23).
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10. Illustration 9 g00997252
Note: Identify the location of seal carrier (25) in the transmission case assembly (23) for
assembly purposes.
14. Remove bolts (26) from seal carrier (25).
15. Install Tooling (A) (not shown) in seal carrier (25). Remove seal carrier (25) and the three
ring seals from the transmission case assembly bore (27).
16. Repeat Step 14 through Step 15 on the three remaining seal carriers (25).
Illustration 10 g00997253
17. Remove seal rings (29) from seal carrier (25).
18. Remove seals (28) from seal carrier (25).
19. Remove spring pin (30) from seal carrier (25).
20. Repeat Step 17 and Step 19 for the remaining three seal carriers (25).
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11. Illustration 11 g00997255
21. Install Tooling (B) in the transmission case assembly (23). Tighten Tooling (B) evenly to
separate transmission case assembly (23) from transmission cover assembly (31).
22. Install Tooling (A) to transmission case assembly (23). Attach a suitable lifting device to
Tooling (A). Slowly raise the transmission case assembly (23) from the transmission cover
assembly (31). Be careful not to bind the transmission case assembly (23) during separation.
Illustration 12 g01022248
23. Remove bolts (32) from tube assembly (33). Remove tube assembly (33) from the
transmission cover assembly (31).
24. Remove the O-ring seal from tube assembly (33).
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12. Illustration 13 g00997257
Note: First/Third shaft assembly (34) and High/Low shaft assembly (35) must be removed
together.
25. Install Tooling (D) on First/Third shaft assembly (34) and High/Low shaft assembly (35).
Use Tooling (C) and Tooling (E) in order to hold Tooling (D) on First/Third shaft assembly
(34) and High/Low shaft assembly (35), as shown. First/Third shaft assembly (34) and
High/Low shaft assembly (35) must be removed together.
26. Attach a suitable lifting device to Tooling (D). Carefully remove First/Third shaft assembly
(34) and High/Low shaft assembly (35) from the transmission cover assembly (31). The
weight of the two shaft assemblies is approximately 177 kg (390 lb).
Illustration 14 g00997258
27. Place First/Third shaft assembly (34) and High/Low shaft assembly (35) on Tooling (F) or
on blocks and remove Tooling (D). Carefully separate First/Third shaft assembly (34) and
High/Low shaft assembly (35). The weight of each shaft assembly is approximately 89 kg
(195 lb).
Illustration 15 g00997259
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13. Illustration 16 g00997261
Note: Place High/Low shaft (35) in a modified work bench or on blocks. Modify a
substantial workbench by cutting a 116.0 ± 2.0 mm (4.60 ± 0.08 inch) clearance hole in the
top of the bench.
Illustration 17 g00997262
Illustration 18 g00997263
Note: Do not attach Tooling (G) to rotor (37). If pressure is applied to rotor (37) with
Tooling (G), rotor (37) will brake. Attach Tooling (G) to gear assembly (38).
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14. 28. With High/Low shaft assembly (35) on the modified work bench or on blocks, use Tooling
(G) in order to remove race and bearing (36), rotor (37), gear assembly (38), and two sleeve
bearings (not shown) from High/Low shaft assembly (35). Press fit bearing (36) and rotor
(37) on High/Low shaft assembly (35).
29. Remove bearing (36), rotor (37), thrust disc (39), and gear assembly (38) from High/Low
shaft assembly (35). Attach Tooling (G) to gear assembly (38). Do not attach Tooling (G) to
rotor (37).
Illustration 19 g00997265
30. Remove thrust disc (40) and the washer from High/Low shaft assembly (35).
Illustration 20 g00997266
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.
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15. 31. Install Tooling (H) and Tooling (K) on High/Low shaft assembly (35) and clutch assembly
(41). Tighten Tooling (J) on Tooling (H) (not shown) in order to compress clutch assembly
(41). Remove two half rings (42) and two lock rings (43) from the High/Low shaft assembly
(35).
32. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch
assembly (41). Remove Tooling (K) and Tooling (H) from High/Low shaft assembly (35)
and clutch assembly (41). The clutch assembly (41) is made up of five clutch plates, six
friction discs, and the hub assembly. Identify the position of the clutch assembly (41) for
assembly purposes.
Illustration 21 g00997267
33. Remove wave spring (45) from High/Low shaft assembly (35).
34. Remove piston (44) from High/Low shaft assembly (35).
Illustration 22 g00997268
35. Remove seal extension ring (47) and seal ring (46) from piston (42).
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16. Illustration 23 g00997270
36. Position High/Low shaft assembly (35), as shown. Place High/Low shaft (35) in the
modified work bench, or on blocks. The weight of High/Low shaft assembly (35) is
approximately 50 kg (110 lb).
37. Install Tooling (L) and Tooling (M) on High/Low shaft assembly (35) and inner bearing
(48). Remove inner bearing (48) from High/Low shaft assembly (35). Remove two thrust
discs (49), two bearing sleeves, and gear assembly (50) from High/Low shaft assembly (35).
Illustration 24 g00997273
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.
38. Remove thrust disc (51) and the washer from High/Low shaft assembly (35).
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17. Illustration 25 g00997275
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.
Note: Tooling (K) is the old style tool that is now modified. Tooling (K) (new style tool)
works without being modified. Tooling (K) may need to be modified so the hole in the top
of the tube will have clearance for Tooling (N).
39. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (35) and clutch assembly
(52). Tighten Tooling (P) on Tooling (N) in order to compress clutch assembly (52).
Remove two half rings (53) and two lock rings (54) from the High/Low shaft assembly (35).
40. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from clutch
assembly (52). Remove Tooling (K) and Tooling (N) from High/Low shaft assembly (35)
and clutch assembly (52). The clutch assembly (52) is made up of eight clutch plates, seven
friction discs, and the hub assembly. Identify the position of the clutch assembly (52) for
assembly purposes.
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19. Illustration 26 g00997276
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.
Note: Tooling (K) is the old style tool that must be modified. Tooling (K) (new style tool)
works without being modified. Tooling (K) may need to be modified so the hole in the top
of the tube will have clearance for Tooling (N).
41. Install Tooling (N) and Tooling (K) on High/Low shaft assembly (35) and balance piston
(55). Tighten Tooling (P) on Tooling (N) in order to compress balance piston (55).
42. Use Tooling (Q) in order to remove retaining ring (56) from High/Low shaft assembly (35).
43. Carefully loosen Tooling (P) on Tooling (N) in order to relieve pressure from balance piston
(55). Remove Tooling (K) and Tooling (N) in order to relieve pressure from High/Low shaft
assembly (35) and balance piston (55).
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20. Illustration 27 g00997277
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.
44. Remove balance piston (55) and seal extension ring (57) from High/Low shaft assembly
(35).
45. Remove fifteen springs (58) from piston (59).
46. Remove piston (59), the seal extension ring (not shown), and a ring seal (not shown) from
High/Low shaft assembly (35).
Illustration 28 g00997278
47. Remove seal ring (60) and seal extension ring (61) from piston (59).
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21. Illustration 29 g00997279
48. Place First/Third shaft assembly (34) on the modified work bench or on blocks. Use Tooling
(F) in order to remove race and bearing (62), thrust disc (not shown), and gear assembly
(63) from First/Third shaft assembly (34).
Illustration 30 g00997280
49. Remove thrust disc (64) and gear assembly (65) from First/Third shaft assembly (34).
Illustration 31 g00997283
50. Remove the sleeve bearing (not shown), thrust disc (66), and washer (67) from First/Third
shaft assembly (34).
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22. Illustration 32 g00997284
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.
51. Install Tooling (H) and Tooling (K) on First/Third shaft assembly (34) and clutch assembly
(68). Tighten Tooling (K) on Tooling (H) in order to compress clutch assembly (68).
Remove two half rings (69) and two lock rings (70) from First/Third shaft assembly (34).
52. Carefully loosen Tooling (J) on Tooling (H) in order to relieve pressure from clutch
assembly (68). Remove Tooling (K) and Tooling (H) from First/Third shaft assembly (34)
and clutch assembly (68). As you remove clutch assembly (68) from First/Third shaft
assembly (34), identify the positions of the five clutch plates, the six friction disc, and the
hub assembly for assembly purposes.
Illustration 33 g00997296
53. Remove wave spring (71) from First/Third shaft assembly (34).
54. Remove piston (72) from First/Third shaft assembly (34).
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23. Illustration 34 g01022249
55. Remove seal extension ring (73) and seal ring (74) from piston (72).
Illustration 35 g00997299
56. Position First/Third shaft assembly (34), as shown. Place First/Third shaft assembly (34) in
the modified work bench, or on blocks. The weight of First/Third shaft assembly (34) is
approximately 55 kg (120 lb).
57. Remove the seal ring (not shown) from First/Third shaft assembly (34).
58. Use Tooling (R) in order to remove inner bearing (75), thrust disc (not shown), gear (76),
and thrust disc (not shown).
59. Remove gear assembly (77), the bearing sleeve (not shown), the thrust disc, and the washer
(not shown) from First/Third shaft assembly (34).
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