Service Repair Manual Models 972G II Wheel Loader
By: A.
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 lines, on all hoses, on all wires, and on all tubes for installation purposes. Plug all lines, hoses, and tubes. This helps to prevent fluid loss and this helps to keep contaminants from entering the system.
Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 972G II WHEEL LOADER AXC Configuration: 972G II Wheel Loader AXC00001-UP (MACHINE) POWERED BY 3196 Engine Disassembly and Assembly 966G Series II and 972G Series II Wheel Loaders Power Train Media Number -RENR4365-07 Publication Date -01/08/2008 Date Updated -14/08/2008 i02299775 Transmission Planetary - Disassemble SMCS - 3160-015 Disassembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7575 Link Bracket 3 B 1P-0520 Driver Gp 1 C 8H-0663 Bearing Puller 1
Start Separate the transmission from the output transfer gears. Refer to Disassembly and Assembly, "Transmission from Output Transfer Gears - Separate".
Illustration 1 g00458960 1. Remove O-ring seal (1) from the housing. 2. Remove bolt (3), retainer (2), and drive gear (4) from the end of the input shaft. Illustration 2 g00459007 3. Remove plate (5) . Illustration 3 g00459030
4. Tooling (A) a suitable lifting device to the transmission, as shown. weight of transmission is 544 kg (1200 lb). position the planetary group on the opposite end clutch housing (6) is facing shown. can result from being struck by propelled by sure to wear all necessary protective equipment. recommended procedure all recommended to
The
approximately
Illustration 4 g00459073 6. Remove retaining ring (8) from output shaft (7) . Illustration 5 g00459075 Personal injury
tooling
upward, as
and use
release the spring force.
and
so that No. 6
Follow the
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parts
Attach
a released spring force. Make
5. Carefully
. 9.
. Illustration 7 g00459087 10.
.
Illustration 6 g00459079 8.
7. Remove bolts (9) and No. 6 clutch housing (6). Mark the location of the long bolts. Remove clutch piston (10) from No. 6 clutch housing (6) Remove seal rings (11) and (12) from clutch piston (10) Remove clutch plate (14) and springs (13)
Illustration 8 g00459090 11. Remove clutch plates (15) and friction discs (16) . Illustration 9 g00459103 12. Remove ring gear (17). Remove transmission speed sensors (18) . Illustration 10 g00459133 13. Remove carrier assembly (19) .
Illustration 11 g00459138 14. Remove metal seal ring (20) from carrier assembly (19) . Illustration 12 g00459150 15. Use a hammer and a punch to push the spring pins through carrier assembly (19) and into planetary shafts (21) .
Illustration 13 g00459151
17. Remove thrust discs (22), planetary gears (23), and bearings (24) from the carrier assembly. Remove spring pins (25) from planetary shafts (21) . 15 g00459161
Illustration
16. Use a hammer and a punch to remove planetary shafts (21) from carrier assembly (19) . 14 g00324725
Illustration
18. Remove O-ring seal (26). Remove bolts (27) from manifold (28) .
Illustration 16 g00565113 19. Disconnect the harness assemblies which are attached to transmission modulating valves (29). Remove transmission modulating valves (29) from the transmission housing. Illustration 17 g00459316 20. Remove retaining ring (32) and gear (30). Remove retaining ring (31) . Illustration 18 g00459322
Illustration 19 g00459352
22. Remove bolt (33) which holds the harness assembly in place.
23. Remove retaining ring (34) and bearing (35) from manifold (28) .
21. Use Tooling (A) and a suitable lifting device to remove manifold (28). The weight of manifold (28) is approximately 85 kg (190 lb).
Illustration 20 g00459369 Remove retaining ring (36) and clutch housing (37) .
24.
Illustration 21 g00459372 25. Remove O-ring seal (38) from clutch housing (37) . Illustration 22 g00459375 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. 26. Use steel spacers and a suitable press to push on retainer plate (40). Remove retaining ring (39) from the clutch housing.
Illustration 23 g00459387 27. Separate retaining ring (39), retainer plate (40), three coned disc springs (41), and clutch piston (42) . Illustration 24 g00459393 28. Remove seal rings (43) from clutch piston (42) . Illustration 25 g00459394
29. Remove seal rings (44) from clutch housing (37) . Illustration 26 g00565119 30. Remove retaining ring (45) from the output shaft. Remove hub (46) . Illustration 27 g00565685 31. Remove friction discs (47) and clutch plates (48) .
Illustration 28 g00565132 32. Remove clutch plate (49) and ring gear (50) . Illustration 29 g00565193 33. Remove springs (51). Remove friction discs (52) and clutch plates (53) . Illustration 30 g00565687 34. Remove clutch piston (54). Remove O-ring seals (55) and (56) .
Illustration 31 g00459506 35. Remove seal rings (57) and (58) from clutch piston (54) . Illustration 32 g00565199 36. Use Tooling (A) and a suitable lifting device to remove housing (59). The weight of housing (59) is approximately 66 kg (145 lb). Note: The clutch piston may be stuck in housing (59). As housing (59) is removed, the clutch piston may fall.
Illustration 33 g00565203 37. Remove clutch piston (60) . Illustration 34 g00459540 38. Remove seal rings (61) and (62) from clutch piston (60) . Illustration 35 g00565255 39. Remove friction discs (63) and clutch plates (64) .
Illustration 36 g00565689 40. Remove O-ring seals (65) and (66). Remove springs (68) and carrier assembly (69). Remove rods (67) . Illustration 37 g00459619 41. Remove gear (70) from carrier assembly (69) . Illustration 38 g00459622
Illustration 40 g00459638 45.
44.
42. Remove retaining ring (71) and bearing (72) . Illustration 39 g00459634
43. Use several small steel rods (73) (3.175 mm (0.1250 inch) diameter and one pointed tip) to compress the retaining ring that holds carrier assembly (69) to ring gear (74) . Remove carrier assembly (69) from ring gear (74) . Remove retaining ring (75) from carrier assembly (69) .
Illustration 41 g00459643 46. Use a hammer and a punch to push the spring pins through carrier assembly (69) and into planetary shafts (76) . 47. Use a hammer and a punch to remove planetary shafts (76) from carrier assembly (69) . Illustration 42 g00459646 48. Remove thrust discs (77), planetary gears (78), and bearings (79) from the carrier assembly. Remove spring pins (80) from planetary shafts (76) .
Illustration 43 g00565272 49. Remove retaining ring (81) that holds output shaft (82) to the input shaft. Remove output shaft (82) . Illustration 44 g00459776 50. Remove O-ring seal (83) from output shaft (82) . Illustration 45 g00460029 51. Remove retaining ring (85) . 52. Remove sun gear (84) from output shaft (82) .
Illustration 46 g00460030 53. Use a suitable press to push output shaft (82) out of bearing (86), as shown. Illustration 47 g00460034 54. If necessary, remove bearings (87) from both ends of output shaft (82) . Illustration 48 g00565282
55. Use Tooling (A) and a suitable lifting device to remove housing (88). The weight of housing (88) is approximately 61 kg (135 lb). Illustration 49 g00460042 56. Remove clutch piston (89), friction discs (90), and clutch plates (91) . Illustration 50 g00460045 57. Remove seal rings (92) and (93) from clutch piston (89) .
Illustration 51 g00460067 58. Remove retaining ring (94) from the input shaft. 59. Remove springs (95) and ring gear (96). Remove O-ring seals (97) and (98) . Illustration 52 g00460068 60. Remove carrier assembly (99) from the input shaft. The weight of the carrier assembly is approximately 29 kg (65 lb).
Illustration 54 g00460078 65.
66.
61. Remove gear (100) . Place a suitable wood block under carrier assembly (99) . Use several small steel rods (101) (2.36 mm (0.093 inch) diameter and one pointed tip) to compress the retaining ring that holds carrier assembly (99) to ring gear (102) together. Remove ring gear (102) from carrier assembly (99) . Remove retaining ring (105) from carrier assembly (99) . Remove retaining ring (104). Remove sun gear (103) and the bearing. Use Tooling (B) to remove sun gear (103) and the bearing. Use a hammer and a punch to push the spring pins through carrier assembly (99) and into planetary shafts (106) .
64.
Illustration 55 g00460081 67.
Illustration 53 g00460074
63.
62.
Illustration 56 g00460134 68. Use a hammer and a punch to remove planetary shafts (106) from carrier assembly (99) . Illustration 57 g00460135 69. Remove thrust discs (107), bearings (109), and planetary gears (108) from the carrier assembly. 70. Remove spring pins (110) from planetary shafts (106) .
Illustration 58 g00460138 71. Remove bearing (111) from sun gear (103) . Illustration 59 g00460141 72. Remove O-ring seal (112) from sun gear (103) . Illustration 60 g00460178 73. Remove plate (113) .
Note: Coupling (120) and carrier assembly (119) may be removed together at this time. Use small steel rods (118) in order to separate coupling (120) and carrier assembly (119). See Step 43 for similar actions.
74. Remove friction discs (114) and clutch plates (117). Remove O-ring seals (115) and (116) .
75. Use several small steel rods (118) (2.36 mm (0.093 inch) diameter and one pointed tip) to compress the retaining ring that holds coupling (120) to carrier assembly (119). Remove coupling (120) from carrier assembly (119) .
Illustration 62 g00460207
Illustration 61 g00460181
Illustration 63 g00460208 76. Remove clutch piston (121) from the clutch housing. Remove carrier assembly (119) . Illustration 64 g00460209 77. Remove seal rings (122) and (123) from clutch piston (121) . Illustration 65 g00460233 78. Remove retaining ring (124). Use Tooling (B) to remove bearing (125) .
79. Remove seal ring (126) from carrier assembly (119) .
Illustration 66 g00460237
80. Use a hammer and a punch to push the spring pins through carrier assembly (119) and into planetary shafts (127) .
81. Use a hammer and a punch to remove planetary shafts (127) from carrier assembly (119) .
82. Remove thrust discs (128), planetary gears (129), and bearings (130) from the carrier assembly. Remove spring pins (131) from planetary shafts (127) .
Illustration 67 g00460313
Illustration 68 g00460315 83. Remove retaining ring (132) from housing (133) . 84. Use a soft hammer to remove input shaft (134) from housing (133) . Illustration 69 g00460318 85. Remove ring seals (136) and O-ring seal (137) from input shaft (134). Remove bearing (135) .
Illustration 70 g00460322
86. Use a suitable press and Tooling (C) to remove race (138) from input shaft (134) . Copyright 1993 - 2021 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Tue May 11 10:16:56 UTC+0800 2021
Shutdown SIS Previous Screen Product: WHEEL LOADER Model: 972G II WHEEL LOADER AXC Configuration: 972G II Wheel Loader AXC00001-UP (MACHINE) POWERED BY 3196 Engine Disassembly and Assembly 966G Series II and 972G Series II Wheel Loaders Power Train Media Number -RENR4365-07 Publication Date -01/08/2008 Date Updated -14/08/2008 i06064263 Transmission Planetary - Assemble SMCS - 3160-016 Assembly Procedure Table 1 Required Tools Tool Part Number Part Description Qty A 138-7575 Link Bracket 3 B 1P-0520 Driver Gp 1 D FT-2746 Guide Pin 2 E 1P-0510 Driver Gp 1 F - Loctite 5127 1 Note: Cleanliness is an important factor. Before assembly, all parts should be 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.
Illustration 1 g00460318
Illustration 2 g00460315
Note: O-ring seal (137) is not installed at this time. The O-ring seal is shown in order to clarify the installation in Step 11.
1. Raise the temperature of bearing (135) and the race. Install bearing (135) and the race onto input shaft (134) , as shown.
3. Carefully install input shaft (134) in housing (133) .
4. Install retaining ring (132) in order to hold the input shaft and the bearing in place.
2. Apply clean transmission oil to ring seals (136) . Install two ring seals (136) on input shaft (134) .
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Illustration 3 g00460313 Illustration 4 g00460237 5. Install bearings (130) in planetary gears (129) . Install the gear assemblies, thrust discs (128) , and planetary shafts (127) in carrier assembly (119) . 6. Use a hammer and a punch to install spring pins (131) that hold planetary shafts (127) in carrier assembly (119) . Make sure that the spring pins are flush with the counterbore in the carrier. Illustration 5 g00460233
Illustration 7 g00460208
Note: Coupling (120) may be installed on carrier assembly (119) at this time. Refer to Step 13 for the procedure. 6
10. Place suitable cribbing under the housing. Install clutch piston (121) in the clutch housing. Make sure that the lips of the seals are facing downward.
8. Use Tooling (B) to install bearing (125) . Install retaining ring (124) .
Illustration
12. Install carrier assembly (119) .
11. Install O-ring seal (137) . Apply clean transmission oil to O-ring seal (137) and the O-ring seal groove on the shaft. Refer to Illustration 1 for the location of the O-ring seal.
9. Install seal rings (122) and (123) on clutch piston (121) .
7. Install seal ring (126) on carrier assembly (119) .
g00460209
Illustration 8 g00460207 13. If necessary, install coupling (120) on carrier assembly (119) . Use small steel rods (118) to compress the retaining ring that holds coupling (120) to carrier assembly (119) . Illustration 9 g00460934 Illustration 10 g00720054 Note: For assembly purposes, use Tooling (D) to hold the clutch plates in place. Do not remove Tooling (D) until Step 85 is completed.
