Service Repair Manual

Models

972K Wheel Loader

972K Wheel Loader PEM00001-UP (MACHINE) POWERED BY C9.3 Engine(SEBP... 1/30

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Product: WHEEL LOADER

Model: 972K WHEEL LOADER PEM
Configuration: 972K Wheel Loader PEM00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

966K and 972K Wheel Loaders Power Train
Media Number -KENR6472-01 Publication Date -01/03/2013 Date Updated -04/03/2013

i03917692

Transmission Planetary - Disassemble

SMCS - 3160-015

S/N - PEM1-UP

S/N - Z4W1-UP

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 By:

A. Separate the transmission from the output transfer gears.

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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

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4. Attach Tooling (A) and a suitable lifting device to the transmission, as shown. The weight
of the transmission is approximately 544 kg (1200 lb).

5. Carefully position the planetary group on the opposite end so that No. 6 clutch housing (6)
is facing upward, as shown.

Illustration 4 g00459073

6. Remove retaining ring (8) from output shaft (7) .

Illustration 5 g00459075

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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7. Remove bolts (9) and No. 6 clutch housing (6). Mark the location of the long bolts.

Illustration 6 g00459079

8. Remove clutch piston (10) from No. 6 clutch housing (6) .

9. Remove seal rings (11) and (12) from clutch piston (10) .

Illustration 7 g00459087

10. Remove clutch plate (14) and springs (13) .

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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) .

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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) .

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Illustration 13 g00459151

16. Use a hammer and a punch to remove planetary shafts (21) from carrier assembly (19) .

Illustration 14 g00324725

17. Remove thrust discs (22), planetary gears (23), and bearings (24) from the carrier assembly.
Remove spring pins (25) from planetary shafts (21) .

Illustration 15 g00459161

18. Remove O-ring seal (26). Remove bolts (27) from manifold (28) .

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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

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21. Use Tooling (A) and a suitable lifting device to remove manifold (28). The weight of
manifold (28) is approximately 85 kg (190 lb).

22. Remove bolt (33) which holds the harness assembly in place.

Illustration 19 g00459352

23. Remove retaining ring (34) and bearing (35) from manifold (28) .

Illustration 20 g00459369

24. Remove retaining ring (36) and clutch housing (37) .

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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 retainer plate (40). Remove retaining ring (39)
from the clutch housing.

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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

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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) .

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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) .

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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.

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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) .

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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

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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) .

44. Remove carrier assembly (69) from ring gear (74) .

Illustration 40 g00459638

45. Remove retaining ring (75) from carrier assembly (69) .

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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) .

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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) .

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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

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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) .

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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).

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Illustration 53 g00460074

61. Remove gear (100) .

62. Place a suitable wood block under carrier assembly (99) .

63. 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.

64. Remove ring gear (102) from carrier assembly (99) .

Illustration 54 g00460078

65. Remove retaining ring (105) from carrier assembly (99) .

66. Remove retaining ring (104). Remove sun gear (103) and the bearing. Use Tooling (B) to
remove sun gear (103) and the bearing.

Illustration 55 g00460081

67. Use a hammer and a punch to push the spring pins through carrier assembly (99) and into
planetary shafts (106) .

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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) .

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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) .

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Illustration 61 g00460181

74. Remove friction discs (114) and clutch plates (117). Remove O-ring seals (115) and (116) .

Illustration 62 g00460207

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) .

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.

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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) .

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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) .

Illustration 67 g00460313

82. Remove thrust discs (128), planetary gears (129), and bearings (130) from the carrier
assembly. Remove spring pins (131) from planetary shafts (127) .

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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) .

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Illustration 70 g00460322

86. Use a suitable press and Tooling (C) to remove race (138) from input shaft (134) .

Copyright 1993 - 2021 Caterpillar Inc. Wed Apr 21 14:44:34 UTC+0800 2021
All Rights Reserved.
Private Network For SIS Licensees.

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Shutdown SIS

Previous Screen

Product: WHEEL LOADER

Model: 972K WHEEL LOADER PEM
Configuration: 972K Wheel Loader PEM00001-UP (MACHINE) POWERED BY C9.3 Engine

Disassembly and Assembly

966K and 972K Wheel Loaders Power Train
Media Number -KENR6472-01 Publication Date -01/03/2013 Date Updated -04/03/2013

i03920170

Transmission Planetary - Assemble

SMCS - 3160-016

S/N - PEM1-UP

S/N - Z4W1-UP

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

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Illustration 1 g00460318

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 and install bearing (135) and the race on
input shaft (134), as shown.

2. Apply clean transmission oil to ring seals (136). Install two ring seals (136) on input shaft
(134) .

Illustration 2 g00460315

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.

Illustration 3 g00460313

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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

7. Install seal ring (126) on carrier assembly (119) .

8. Use Tooling (B) to install bearing (125). Install retaining ring (124) .

Note: Coupling (120) may be installed on carrier assembly (119) at this time. Refer to Step
13 for the procedure.

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Illustration 6 g00460209

9. Install seal rings (122) and (123) on clutch piston (121) .

Illustration 7 g00460208

10. Place wood blocks under the housing. Install clutch piston (121) in the clutch housing.
Make sure that the lips of the seals are facing downward.

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.

12. Install carrier assembly (119) .

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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.

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Enter the link into your browser.
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download.

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