Caterpillar cat 938 g ii wheel loader (prefix crd) service repair manual (crd00001 and up)

Service Repair Manual
Models
938G II Wheel Loader

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Product: WHEEL LOADER
Model: 938G II WHEEL LOADER CRD
Configuration: 938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine
Disassembly and Assembly
938G Series II Wheel Loader and IT38G Series II Integrated Toolcarrier Power
Train
Media Number -RENR6068-03 Publication Date -01/12/2008 Date Updated -19/12/2008
i01879674
Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
B
3H-0465 Push-Puller Plate 4
5F-7344 Puller Block 1
5P-8715 Forcing Bolt 1
8B-7550 Push-Puller Leg 2
8H-0663 Bearing Puller Gp 1
C 1P-2420 Transmission Repair Stand 1
D 2P-8312 Retaining Ring Pliers 1
E 8S-2328 Dial Indicator Gp 1
F 9U-7480 Compressing Tube 1
G 1P-1863 Retaining Ring Pliers 1
H 9U-7479 Compressing Tube 1
J 1U-6341 Threaded Rod 1
K 5P-7970 Nut 1
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L 154-6182 Forcing Bolt 1
Start By:
A. Separate the transmission from the torque converter. Refer to Disassembly and Assembly,
"Transmission and Torque Converter - Separate".
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Tools and Shop
Products Guide" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
Note: Put identification marks on all sections of the transmission for assembly purposes.
Illustration 1 g00984312
1. Install Tooling (A) to shaft (1). Attach a suitable lifting device to Tooling (A) .
Note: Hold input shaft (2) away from shaft (1) for clearance.
2. Use a suitable lifting device to lift shaft (1) straight up out of transmission case. The weight
of shaft (1) is approximately 50 kg (110 lb).
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3. Position shaft (1) on Tooling (C), as shown.
4. Use Tooling (D) to remove retaining ring (3) and remove thrust disc (4) .
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5. Remove gear and hub assembly (5) .
6. Use Tooling (G) to remove retaining ring (6) .
7. Separate hub (7) from gear (5). If necessary, remove sleeve bearing (8) .
8. Remove thrust disc (9) and retainer (10) .
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9. Use Tooling (D) to remove retaining ring (11) .
10. Use a screwdriver to remove retaining ring (12) .
11. Remove one end plate (13), clutch plates (14), and friction discs (15) .
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12. End plate (13), clutch plates (14), and friction plates (15) .
13. Position the shaft assembly with retaining ring (16) in line with the opening in Tooling (F) .
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14. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. The
wave spring is not shown. Use Tooling (D) to remove retaining ring (16). Remove Tooling
(F) .
15. Remove balance seal assembly (17) .
16. Remove wave spring (18) .
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17. Remove piston assembly (19) .
18. Balance seal assembly (17). Wave spring (18) will be removed with piston (19). Check the
lips on the seals for damage or wear. Replace the seals if it is necessary.
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19. Reposition the shaft assembly, as shown. Remove three seal rings (20). Use Tooling (D) to
remove retaining ring (21) .
20. Remove thrust disc (22) .
21. Remove washer (23) and gear (24) .
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22. Remove spacer assembly (25) .
23. Remove thrust disc (26), the gear, and hub assembly (27) .
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938G II Wheel Loader CRD00001-UP (MACHINE) POWERED BY 3126B Engine...
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24. Use Tooling (G) to remove retaining ring (28). Separate gear (27) from hub assembly (29).
If necessary, remove sleeve bearing (30) .
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29. Exploded view of end plate (35), clutch plates (36), and friction discs (37) upon removal.
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30. Position the shaft assembly with the opening in retaining ring (38) in line with the opening
in Tooling (F) .
wave spring is not shown.
32. Use Tooling (D) to remove retaining ring (38) and remove Tooling (F) .
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35. Remove piston seal (41) .
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36. Remove seal rings (41A) and (41B) from piston (41). Replace the seals, if necessary.
37. Use Tooling (A) and a suitable lifting device in order to remove shaft assembly (42). The
weight of shaft assembly is approximately 41 kg (90 lb).
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38. Position shaft (42) on Tooling (C), as shown.
39. Use Tooling (D) to remove retaining ring (43) and remove thrust disc (44) .
40. Remove gear and hub assembly (45) .
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41. Use Tooling (G) to remove retaining ring (46). Separate gear (45) from hub assembly (47).
Remove sleeve bearing (48), if necessary.
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46. Position the shaft so the opening in retaining ring (56) will line up with the opening in
Tooling (F) .
47. Install Tooling (F), Tooling (J), and Tooling (K) in order to compress the wave spring. Use
Tooling (D) to remove the retaining ring (56). Remove Tooling (F) .
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50. Remove piston assembly (59) .
51. Remove seal rings (59A), and (59B) from piston (59). Replace the seals if it is necessary.
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52. Position the shaft assembly with the opposite end upward, as shown. Remove three seal
rings (60). Use Tooling (D) to remove retaining ring (61) .
53. Remove thrust disc (62) and gear assembly (63) .
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54. Remove two sleeve bearings (64), if necessary.
56. Use Tooling (D) to remove retaining ring (67). Use a screwdriver to remove retaining ring
(68) .
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58. End plate (69), clutch plates (70), and friction discs (71) upon removal.
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59. Position the shaft assembly so the opening in retaining ring (72) will be in line with the
opening in Tooling (F) .
wave spring is not shown. Use Tooling (G) to remove retaining ring (72). Remove Tooling
(F) .
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63. Remove piston seal (75) .
64. Remove seal rings (76) and (77) from piston (75). Replace the seals if it is necessary.
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Caterpillar cat 938 g ii wheel loader (prefix crd) service repair manual (crd00001 and up)

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