Caterpillar Cat 966G WHEEL LOADER (Prefix 8XW) Service Repair Manual (8XW00001-00346)

1
Service Repair Manual
Models 966G WHEEL LOADER
2
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Product WHEEL LOADER Model 966G WHEEL LOADER
8XW Configuration 966G WHEEL LOADER
8XW00001-00346 (MACHINE) POWERED BY 3306 ENGINE
Disassembly and Assembly 966G and 972G Wheel
Loaders Power Train Media Number
-RENR2106-08 Publication Date -01/05/2004
Date Updated -28/05/2004
i02299775
Transmission Planetary - Disassemble SMCS -
3160-015 Disassembly Procedure Table 1
Required Tools Required Tools Required Tools 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. Refer to Disassembly and
Assembly, "Transmission from Output Transfer
Gears - Separate". 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.
3

• Illustration 1 g00458960
• Remove O-ring seal (1) from the housing.
• 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

1. Attach Tooling (A) and a suitable lifting device
   to the transmission, as shown. The weight of the
   transmission is approximately 544 kg (1200 lb).
2. 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.
5
7. Remove bolts (9) and No. 6 clutch housing (6).
Mark the location of the long bolts.

• Illustration 6 g00459079
• Remove clutch piston (10) from No. 6 clutch
  housing (6) .
• 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) .
8
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) .
9
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) .
10
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
11

1. Use Tooling (A) and a suitable lifting device to
   remove manifold (28). The weight of manifold
   (28) is approximately 85 kg (190 lb).
2. 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) .
12
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.
13
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
14
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) .
15
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) .
16
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.
17
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) .
18
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
19
42. Remove retaining ring (71) and bearing (72) .

• Illustration 39 g00459634
• 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) .

Illustration 40 g00459638 45. Remove retaining
ring (75) from carrier assembly (69) .
20

• Illustration 41 g00459643
• Use a hammer and a punch to push the spring pins
  through carrier assembly (69) and into planetary
  shafts (76) .
• 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) .
21
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

1. Remove retaining ring (85) .
2. Remove sun gear (84) from output shaft (82) .

22
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
23
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) .
24

• Illustration 51 g00460067
• Remove retaining ring (94) from the input shaft.
• 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).
25
Illustration 53
g00460074

1. Remove gear (100) .
2. Place a suitable wood block under carrier
   assembly (99) .
3. 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.
4. Remove ring gear (102) from carrier assembly (99)
   .

• Illustration 54 g00460078
• 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.

Illustration 55 g00460081 67. Use a hammer and a
punch to push the spring pins through carrier
assembly (99) and into planetary shafts (106) .
26
Illustration 56 g00460134 68. Use a hammer and a
punch to remove planetary shafts (106) from
carrier assembly (99) .

• Illustration 57 g00460135
• Remove thrust discs (107), bearings (109), and
  planetary gears (108) from the carrier assembly.
• Remove spring pins (110) from planetary shafts
  (106) .

27
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) .
28
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.
29
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) .
30
79. Remove seal ring (126) from carrier assembly
(119) .

• Illustration 66 g00460237
• Use a hammer and a punch to push the spring pins
  through carrier assembly (119) and into
  planetary shafts (127) .
• 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) .
31

• Illustration 68 g00460315
• Remove retaining ring (132) from housing (133) .
• 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) .
32
Illustration 70 g00460322 86. Use a suitable
press and Tooling (C) to remove race (138) from
input shaft (134) .
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33
Shutdown SIS
Previous Screen
Product WHEEL LOADER Model 966G WHEEL LOADER
8XW Configuration 966G WHEEL LOADER
8XW00001-00346 (MACHINE) POWERED BY 3306 ENGINE
Disassembly and Assembly 966G and 972G Wheel
Loaders Power Train Media Number
-RENR2106-08 Publication Date -01/05/2004
Date Updated -28/05/2004
i06064263
Transmission Planetary - Assemble SMCS -
3160-016 Assembly Procedure Table 1
Required Tools Required Tools Required Tools 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.
34

• 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.
• Raise the temperature of bearing (135) and the
  race. Install bearing (135) and the race onto
  input shaft (134) , as shown.
• Apply clean transmission oil to ring seals (136)
  . Install two ring seals (136) on input shaft
• (134) .

• Illustration 2 g00460315
• Carefully install input shaft (134) in housing
  (133) .
• Install retaining ring (132) in order to hold the
  input shaft and the bearing in place.

35
Illustration 3
g00460313

• Illustration 4 g00460237
• Install bearings (130) in planetary gears (129) .
  Install the gear assemblies, thrust discs
• (128) , and planetary shafts (127) in carrier
  assembly (119) .
• 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
36

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

Illustration 6 g00460209 9. Install seal rings
(122) and (123) on clutch piston (121) .

• Illustration 7 g00460208
• 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.
• 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.
• Install carrier assembly (119) .

37
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.
38
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• Install one clutch plate (117) in the housing so
  that the small hole in the clutch plate is
  aligned with the small hole in the housing, as
  shown.
• Install Tooling (D) in two of the five threaded
  holes in the housing through clutch plate
• (117) , as shown. Do not remove Tooling (D) until
  Step 85 is completed.
• Install friction discs (114) and clutch plates
  (117) in alternating order. Start with a friction
  disc. Install clutch plates (117) so that
  Tooling (D) passes through the bolt holes in the
  clutch plates. Install the clutch plates with the
  small holes on the opposite side of Tooling
• (D) in comparison to the first clutch plate (117)
  that was installed in Step 14.
• Install O-ring seals (115) and (116) .

Illustration 11
g00460178
18. Install plate (113) .
Illustration 12
g00460135
40

• Illustration 13 g00460081
• Install bearings (109) in planetary gears (108) .
  Install the gear assemblies, thrust discs
• (107) , and planetary shafts (106) in carrier
  assembly (99) .
• Use a hammer and a punch to install spring pins
  (110) that hold planetary shafts (106) in
  carrier assembly (99) . Make sure that the spring
  pins are flush with the counterbore in the
  carrier.

Illustration 14
g00460141
Illustration 15
g00569395
41

• Use Tooling (B) and a press to install bearing
  (111) . Install retaining ring (104) .
• Install O-ring seal (112) on sun gear (103) .
  Apply clean transmission oil to O-ring seal
• (112) and the O-ring seal groove on sun gear
  (103) .
• Install sun gear (103) in carrier assembly (99) .
• Install retaining ring (105) on carrier assembly
  (99) .

Illustration 16 g00460074 Note Gear (100) is
not installed at this time. The gear is shown in
order to clarify the installation in Step
27. 25. Use small steel rods (101) to compress
the retaining ring. Install carrier assembly (99)
in ring gear (102) until the retaining ring fits
into the groove in the ring gear.

• Illustration 17 g00720063
• Install carrier assembly (99) on the input shaft.
  The weight of the carrier assembly is
  approximately29 kg (65 lb).
• Install gear (100) .

42
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