Caterpillar Cat 972H Wheel Loader (Prefix GTA) Service Repair Manual (GTA00001 and up)

1
Service Repair Manual
Models 972H Wheel Loader
2
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Product WHEEL LOADER Model 972H WHEEL LOADER
GTA Configuration 972H Wheel Loader GTA00001-UP
(MACHINE) POWERED BY C13 Engine
Disassembly and Assembly 966H and 972H Wheel
Loaders Power Train Media Number
-RENR8847-07 Publication Date -01/03/2013
Date Updated -04/03/2013
i06064263
Transmission Planetary - Assemble SMCS - 3160-016
S/N - A7D1-UP S/N - A7G1-UP S/N - A7J1-UP S/N -
GTA1-UP S/N - LCC1-UP 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.
3

• 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.

4
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
5

• 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) .

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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.
8

• 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
9

• 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
10

• 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) .

11
Illustration 18
g00460067

• Typical Example
• Do Not Remove Tooling (D) Until Step 85 is
  Completed.
• Install retaining ring (94) on the input shaft.
• Install ring gear (96) .
• Install O-ring seals (97) and (98) . Install
  springs (95) .

Illustration 19 g00460045 31. Install seal rings
(92) and (93) on clutch piston (89) .
12

• Illustration 20 g01151694
• Install friction discs (90) and clutch plates
  (91) in alternating order. Start with a friction
  disc. Start with a friction disc. Install clutch
  plates (91) so that Tooling (D) passes through
  the bolt holes in the clutch plates. Install the
  last clutch plate so that the small holes in the
  clutch plate are over springs (95) , as shown.
  Install rods (67) .
• Install clutch piston (89) . Make sure that the
  lips of the seals are facing upward.

Illustration 21
g00565282
Typical Example Do Not Remove Tooling (D) Until
Step 85 is Completed. 34. Use Tooling (A) and a
suitable lifting device to install housing (88) .
The weight of housing (88) is approximately 61 kg
(135 lb).
13
Illustration 22 g00460034 35. If bearings (87)
were removed, lower the temperature of the two
bearings. Then, put the bearings in position in
both ends of output shaft (82) .
Illustration 23
g01153103
36. Use Tooling (E) to install bearings (87)
. Note For the 966F, install the bearing to a
depth of 12.0 0.5 mm (0.47 0.02 inch) on the
gear end of the output shaft. After assembly, the
inside diameter of bearing (87) must be 34.988
0.039 mm (1.3775 0.0015 inch). Repeat for the
opposite end of the output shaft. Note For the
972F, install the bearing to a depth of 13.00
0.25 mm (0.512 0.010 inch) on the gear end of
the output shaft. After assembly, the inside
diameter of bearing (87) must be 56.650 0.061
mm (2.2303 0.0024 inch). Install the bearing on
the other end of the output shaft to a depth of
25.50 0.25 mm (1.004 0.010 inch). After
assembly, the inside diameter of bearing must be
35.629 0.039 mm (1.4028 0.0016 inch).
14
Illustration 24 g00461572 Note Make sure that
the locating dowel fits into the notch in the
bearing. Also, the groove in the bearing must
face the top of the output shaft. 37. Raise the
temperature of bearing (86) and install the
bearing on output shaft (82) .
Illustration 25
g00460029

1. Install sun gear (84) on output shaft (82) .
2. Install retaining ring (85) .

15
Illustration 26 g00459776 40. Install O-ring
seal (83) on output shaft (82) .

• Illustration 27 g00720135
• Install output shaft (82) over the input shaft.
• Install retaining ring (81) that holds output
  shaft (82) to the carrier assembly.

Illustration 28
g00459646
16

• Illustration 29 g00459643
• Install bearings (79) in planetary gears (78) .
  Install the gear assemblies, thrust discs (77) ,
  and planetary shafts (76) in carrier assembly
  (69) .
• Use a hammer and a punch to install spring pins
  (80) that hold planetary shafts (76) in carrier
  assembly (69) . Make sure that the spring pins
  are flush with the counterbore in the carrier.

Illustration 30 g00459638 45. Install retaining
ring (75) on carrier assembly (69) .
17
Illustration 31 g00459634 46. Use steel rods
(73) to compress the retaining ring. Install
carrier assembly (69) in ring gear (74) until the
retaining ring fits into the groove in the ring
gear.
Illustration 32 g00459622 47. Install bearing
(72) and retaining ring (71) .
Illustration 33
g00459619
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48. Install gear (70) in carrier assembly (69) .

• Illustration 34 g01151699
• Install carrier assembly (69) . Make sure that
  all of the gear teeth are correctly engaged.
• Install springs (68) . Install O-ring seals (65)
  and (66) .
• Install friction discs (63) and clutch plates
  (64) in alternating order. Install clutch plates
  (64) so that Tooling (D) passes through the bolt
  holes in the clutch plates. Install the last
  clutch plate so that the small holes in the
  clutch plate are over springs (68) , as shown.
  Start with a friction disc.

Illustration 35 g00459540 52. Install seal rings
(61) and (62) on clutch piston (60) .
19
Illustration 36 g00720165 53. Install clutch
piston (60) . Make sure that the lips of the
seals are facing upward. Note Clutch piston (60)
may be installed in housing (59) before the
housing is placed in position.
Illustration 37
g00565199
Typical Example Do Not Remove Tooling (D) Until
Step 85 is Completed. 54. Use Tooling (A) and a
suitable lifting device to install housing (59) .
The weight of housing (59) is approximately 66 kg
(145 lb).
20
Illustration 38 g00459506 55. Install seal rings
(57) and (58) on clutch piston (54) .

• Illustration 39 g00720171
• Install clutch piston (54) . Make sure that the
  lips of the seals are facing downward.
• Install hub (46) . Install retaining ring (45) on
  the output shaft.
• Install O-ring seals (55) and (56) .

21
Illustration 40 g00720321 59. Install friction
discs (52) and clutch plates (53) in alternating
order. Install clutch plates (53) so that Tooling
(D) passes through the bolt holes in clutch
plates (53) . Install the first clutch plate so
that the pins pass through the small holes in the
clutch plate, as shown. Start with a clutch plate.
Illustration 41 g00720327 60. Install ring gear
(50) and clutch plate (49) .
Illustration 42 g00565685 61. Install friction
discs (47) and clutch plates (48) in alternating
order. Start with a friction disc.
22
Illustration 43 g00459393 62. Install seal rings
(43) on clutch piston (42) .
Illustration 44
g00459387
Illustration 45
g00459375
23
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.

1. Stack clutch piston (42) , coned disc springs
   (41) , and retainer plate (40) on the clutch
   housing. Make sure that the outside edges of the
   coned disc springs contact each other first.
2. Use steel spacers and a press to push on retainer
   plate (40) . Install retaining ring (39) on the
   clutch housing.

Illustration 46 g00459394 65. Install seal rings
(44) on clutch housing (37) . Note Each seal
ring has a small gap. The gaps on the different
seal rings should not be in line with each other.
Illustration 47
g00459372
24
66. Install O-ring seal (38) on clutch housing
(37) .
Illustration 48 g00720343 67. Install clutch
housing (37) in the ring gear. Install retaining
ring (36) . Install springs (51) .
Illustration 49 g00459352 68. Lower the
temperature of bearing (35) . Install bearing
(35) in manifold (28) . Install retaining ring
(34) .
25
Illustration 50
g00459322

• Typical Example
• Do Not Remove Tooling (D) Until Step 85 is
  Completed.
• Use Tooling (A) and a suitable lifting device to
  install manifold (28) . The weight of manifold
  (28) is approximately 85 kg (190 lb).
• Note When installing manifold (28) ensure proper
  alignment of dowel on output shaft (82) in notch
  of bearing (35) .
• Install bolt (33) which holds the harness
  assembly in place.

Illustration 51
g00462047
Typical Example Do Not Remove Tooling (D) Until
Step 85 is Completed.
26

• Illustration 52 g00459316
• Install retaining ring (32) on the output shaft.
• Install gear (30) . Use two screwdrivers to lift
  the clutch housing. Install retaining ring (31) .

Illustration 53
g00720354

• Typical example
• Apply Tooling (F) to both sides of the washers
  for bolts (27) . Install bolts (27) in manifold
• (28) . Tighten bolts (27) to a torque of 280 20
  Nm (207 15 lb ft).
• Install O-ring seal (26) .

27
Illustration 54
g00324725

• Illustration 55 g00459150
• Install bearings (24) in planetary gears (23) .
  Install the gear assemblies, thrust discs (22)
  and planetary shafts (21) in carrier assembly
  (19) .
• Use a hammer and a punch to install spring pins
  (25) that hold planetary shafts (21) in carrier
  assembly (19) . Make sure that the spring pins
  are flush with the counterbore in the carrier.

Illustration 56
g00459138
28
77. Install metal seal ring (20) in carrier
assembly (19) .
Illustration 57
g00720364
78. Install carrier assembly (19) .
Illustration 58
g00720368

1. Install ring gear (17) .
2. Install transmission speed sensors (18) , the
   seals, and the washers. Refer to Testing and
   Adjusting, RENR4387, "Speed Sensor (Transmission)
   - Adjust". Tighten the locknuts. The torque for
   the locknuts is 25 5 Nm (220 45 lb in).

29

• Illustration 59 g00720388
• Install clutch plates (15) and friction discs
  (16) in alternating order. Install clutch plates
  (15) so that the guide pins pass through the bolt
  holes in the clutch plates. Start with a friction
  disc.
• Install springs (13) and clutch plate (14) . Make
  sure that clutch plate (14) is installed so that
  the small holes are over springs (13) , as shown.

• Illustration 60 g00459079
• Install seal rings (11) and (12) on clutch piston
  (10) .
• Install clutch piston (10) in No. 6 clutch
  housing (6) . Make sure that the lips of the
  seals are facing downward.

30
Illustration 61 g00720402 85. Install No. 6
clutch housing (6) and five new bolts (9) .
Tighten bolts (9) until bolts (9) are snug.
Remove Tooling (D) .
Illustration 62 g00720411 86. Install the two
remaining bolts (9) . Tighten bolts (9) to a
torque of 110 10 Nm (80 7 lb ft).
Illustration 63
g00459073
31
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32
87. Install retaining ring (8) on output shaft
(7) .
Illustration 64
g00462148
Typical Example 88. Apply 690 to 1030 kPa (100
to 150 psi) of shop air pressure into each oil
passage (140) (total of six). If the clutch
pistons do not move, apply a small amount of
clean transmission oil in each oil passage and
check for movement again. If the clutch pistons
do not move, the transmission must be
disassembled again so that the clutch pistons and
the seal rings can be checked. Note The mounting
surfaces for the transmission modulating valves
must be completely clean. Clean the surfaces
before installation of the transmission
modulating valves.

• Illustration 65 g00565113
• Install transmission modulating valves (29) on
  the transmission housing. The torque for the
  mounting bolts is 30 4 Nm (265 35 lb in).
• Connect the harness assemblies which attach to
  the transmission modulating valves.

33
Illustration 66 g00459030 91. The No. 6 clutch
housing (6) is facing upward. Use Tooling (A) and
a suitable lifting device to position the
transmission onto the opposite end so that the
No. 1 clutch housing is facing upward. The weight
of the transmission is approximately 544 kg (1200
lb).
Illustration 67
g00459007
92. Install plate (5) .
34

• Illustration 68 g00458960
• Install drive gear (4) on the end of the input
  shaft, as shown.
• Install retainer (2) and bolt (3) . Tighten bolt
  (3) to a torque of 100 20 Nm (75 15 lb ft).
• Apply clean transmission oil on O-ring seal (1) .
  Install O-ring seal (1) on the housing.
• End By Connect the transmission to the output
  transfer gears. Refer to Disassembly and
  Assembly, "Transmission to Output Transfer Gears
  - Connect".

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