2. Shutdown SIS
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Product: WHEEL LOADER
Model: 938G WHEEL LOADER 4YS
Configuration: 938G Wheel Loader 4YS00001-UP (MACHINE) POWERED BY 3126 Engine
Disassembly and Assembly
IT38G Integrated Toolcarrier and 938G Wheel Loader Power Train
Media Number -SENR6787-07 Publication Date -01/08/2007 Date Updated -06/08/2007
i01382038
Transmission - Disassemble
SMCS - 3030-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 138-7573 Link Bracket 1
B 8B-7548 Push-Puller Tool 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
I 1U-6341 Threaded Rod 1
J 5P-7970 Nut 1
Start By:
A. Separate the transmission from the torque converter. Refer to Disassembly and Assembly,
"Transmission and Torque Converter - Separate".
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3. 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.
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.
1. Drain the transmission fluid into a suitable container for storage or disposal. The capacity of
the transmission is 30 L (8 US gal).
Illustration 1 g00730160
2. Remove bolt (2), retainer (3), and yoke (4) .
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4. Illustration 2 g00743708
3. Remove bolts (5) and remove retainer (6). Check O-ring seal (7) for damage or wear.
Replace the seal, if it is necessary. The O-ring seal (7) is located behind retainer (6).
Remove brake drum (8) .
Illustration 3 g00743715
4. Remove four bolts (9). Remove tube assembly (10) .
5. Check O-ring seal (11) for damage or wear. The O-ring seal (11) is located on each end of
the tube assembly. Replace the seal if it is necessary.
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5. Illustration 4 g00747980
6. Remove the transmission cover.
Illustration 5 g00730163
7. Install Tooling (A) to shaft (13). Attach a hoist and a suitable lifting sling to Tooling (A) .
Note: Hold input shaft (12) away from shaft (13) for clearance.
8. Use the hoist to lift shaft (13) straight up out of transmission case. The weight of shaft (13)
is 41 kg (90 lb).
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6. Illustration 6 g00730182
9. Install Tooling (A) to shaft (15). Attach a hoist and a suitable lifting sling to Tooling (A) .
Note: Hold input shaft (1) away from shaft (4) for clearance.
10. Use the hoist to lift shaft (4) straight up out of transmission case. The weight of shaft (15) is
46 kg (101 lb).
Illustration 7 g00730186
11. Install Tooling (A) to input shaft (12). Attach a hoist and a suitable lifting sling to Tooling
(A) .
12. Use the hoist to carefully remove input shaft (1) from transmission case (3). The weight of
the input shaft is 17 kg (37.5 lb).
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7. Illustration 8 g00730198
13. Install Tooling (A) to output shaft (16). Attach a hoist and a suitable lifting sling to Tooling
(A) .
14. Use the hoist to carefully remove output shaft (17) from transmission case. The weight of
the output shaft is 80 kg (176 lb).
Illustration 9 g00747113
15. Remove thrust disc (150) from transmission case (14) .
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8. Illustration 10 g00730210
16. Install Tooling (B). Remove bearing (17) from output shaft (18) .
Illustration 11 g00730212
17. Position shaft assembly (16) on Tooling (C) .
Illustration 12 g00730214
18. Use Tooling (D) to remove retaining ring (19). Remove thrust disc (20) .
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9. Illustration 13 g00730217
19. Remove gear (21) .
Illustration 14 g00743729
20. Use Tooling (D) to remove retaining ring (22) .
21. Separate hub assembly (23) from gear (21). Remove sleeve bearing (24), if it is necessary.
Illustration 15 g00743739
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10. 22. Remove thrust disc (25) and retainer (26) .
Illustration 16 g00730219
23. Use Tooling (D) to remove retaining ring (27) .
Illustration 17 g00744470
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11. Illustration 18 g00744313
Typical Example
(W) End plate. (X) Retaining ring. (Z) Oil passage. (Y) Running clearance.
24. Use Tooling (E), a suitable air supply and the following procedure to measure the running
clearance of the clutch pack:
a. Place the shaft in the vertical position. End plate (W) that will be measured should be
facing upward.
b. Make sure that end plate (W) is free.
c. Position the tip of Tooling (E) on end plate (W). Zero Tooling (E) .
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12. Personal injury can result from applying air pressure without the lock
ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come
out with great force.
Make sure lock ring is securely in place before applying air pressure to
clutch pack.
d. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (Z) in the
shaft for the clutch that is being checked.
e. End plate (W) should move upward and end plate (W) should contact retaining ring
(X). The dial indicator will display the distance between end plate (W) and retaining
ring (X). This is the running clearance of the clutch pack. For the proper running
clearance, refer to the Testing and Adjusting, "Transmission Clutch Running
Clearance - Check" for the machine that is being serviced.
Illustration 19 g00744201
25. Use a screwdriver to remove retaining ring (28) .
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13. Illustration 20 g00744226
Illustration 21 g00744206
26. Remove one end plate (29), clutch plates (31), and disc assembly (30) .
Illustration 22 g00744228
27. Install Tooling (F), Tooling (I), and Tooling (J) in order to compress the wave spring. The
wave spring is not shown.
28. Use Tooling (D) to remove retaining ring (32). Release the pressure on the wave spring and
remove Tooling (F) .
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15. 31. Apply suitable air pressure to the passage in order to move piston (35) upward. Remove
piston (35) from shaft (2) .
Illustration 26 g00744343
32. Balance seal assembly (33), wave spring (34), and piston (35) upon removal. Check the lips
on the seals for damage or wear. Replace the seals if it is necessary.
Illustration 27 g00744358
33. Use a lifting eyebolt, and a hoist in order to turn the shaft to the opposite side.
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16. Illustration 28 g00744346
34. Remove four seal rings (36) .
Illustration 29 g00744366
35. Remove the thrust disc (37) .
Illustration 30 g00744373
36. Use Tooling (D) to remove retaining ring (38) .
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18. Illustration 33 g00744383
39. Remove gear and hub assembly (41) .
Illustration 34 g00744424
Illustration 35 g00744385
40. Use Tooling (G) to remove retaining ring (42) .
41. Separate hub assembly (43) from gear (41) .
42. If necessary, remove sleeve bearing (44) .
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19. Illustration 36 g00744456
43. Remove thrust disc (45) and ring retainer (46) .
Illustration 37 g00744470
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21. Illustration 38 g00744313
Typical Example
(Z) Oil passage. (W) End plate. (X) Retaining ring. (Y) Running clearance.
44. Use Tooling (E), a suitable air supply and the following procedure to measure the running
clearance of the clutch pack:
a. Place the shaft in the vertical position. End plate (W) that will be measured should be
facing upward.
b. Make sure that end plate (W) is free.
c. Position the tip of Tooling (E) on end plate (W). Zero Tooling (E) .
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22. Personal injury can result from applying air pressure without the lock
ring securely in place.
If the lock ring is not secure, the end plate and discs can suddenly come
out with great force.
Make sure lock ring is securely in place before applying air pressure to
clutch pack.
d. Apply air pressure of approximately 140 kPa (20 psi) to appropriate passage (Z) in the
shaft for the clutch that is being checked.
e. End plate (W) should move upward and end plate (W) should contact retaining ring
(X). The dial indicator will display the distance between end plate (W) and retaining
ring (X). This is the running clearance of the clutch pack. For the proper running
clearance, refer to the Testing and Adjusting, "Transmission Clutch Running
Clearance - Check" for the machine that is being serviced.
Illustration 39 g00744473
45. Use a screwdriver to remove retaining ring (47) .
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23. Illustration 40 g00744501
46. Remove one end plate (48), clutch plates (49) and friction discs (50) .
Illustration 41 g00744504
47. End plate (48), clutch plates (49), and friction discs (50) upon removal.
Illustration 42 g00744508
48. Use Tooling (G) to remove snap ring (51) .
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