770 and 772 Off-Highway Trucks Power Train Differential and Bevel Gear - Disassemble Caterpillar


Differential and Bevel Gear - Disassemble
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1.1. Disassembly Procedure

Disassembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
138-7576  Link Bracket 
1P-2420  Transmission Repair Stand 
154-6183  Forcing Bolt 
FT-2712  Guide Bolt 
138-7574  Link Bracket 
154-6181  Forcing Screw 
4C-5660  Adapter 
3H-6455 Saddles 
1P-1820 Puller Group 
150-1782 Crossblock 
8B-7549 Puller Leg 
1B-4207 Full Nut 
1P-0510 Driver Gp 
3S-6224 Electric Hydraulic Pump Gp 
138-7573  Link Bracket 
1H-3107  Push-Puller Tool Gp 
1H-3108 Push-Puller Leg 
1P-1820 Puller Group 
3S-6224 Electric Hydraulic Pump Gp 
1H-3110 Bearing Puller Gp 
1P-0510 Driver Gp 
154-6182  Forcing Bolt 
138-7575  Link Bracket 
1H-3110  Bearing Puller Gp 
1H-3107 Push-Puller Tool Gp 
1H-3108 Push-Puller Leg 
1P-0820 Hydraulic Puller 
1P-0520 Driver Gp 
3S-6224 Electric Hydraulic Pump Gp 
5P-1730  Holding Fixture 
5S-6080  Socket 

Start By:

  1. Remove the differential and the bevel gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Remove".


    Illustration 1g01412892

  1. Use Tooling (A) and a suitable lifting device in order to position differential assembly (1) onto Tooling (B). The weight of differential assembly (1) is approximately 839 kg (1850 lb).


    Illustration 2g01412897

  2. Remove bolts (2).


    Illustration 3g01412900

  3. Install Tooling (C). Install Tooling (D) and remove the remaining bolts (2). Use Tooling (C) in order to separate pinion assembly (3) from the differential housing.


    Illustration 4g01412918

  4. Attach Tooling (E) and a suitable lifting device to pinion assembly (3). The weight of pinion assembly (3) is approximately 122 kg (270 lb).

  5. Remove pinion assembly (3) and shims (4). Note the number of shims for installation purposes.


    Illustration 5g01413083

  6. Remove bolt (5) and the retainer.


    Illustration 6g01413087

  7. Remove shims (7). Note the number of shims for installation purposes. Remove O-ring seal (8).

  8. Remove yoke (6).


    Illustration 7g01413090


    Illustration 8g01413092

  9. Remove bolts (9). Install Tooling (F) in order to separate retainer (10) from the pinion assembly.


    Illustration 9g01413102

  10. Remove seal (11) and remove O-ring seal (12).


    Illustration 10g01413126

  11. Use Tooling (G ) in order to remove bearing cone (13).


    Illustration 11g01413149

  12. Attach Tooling (H) and a suitable lifting device to pinion housing (14). The weight of pinion housing (14) is approximately 59 kg (130 lb).

  13. Remove pinion housing (13).


    Illustration 12g01413166

  14. Remove bearing cups (15). Remove O-ring seal (16).


    Illustration 13g01413176

  15. Use Tooling (J) in order to remove bearing cone (17).


    Illustration 14g01413395

  16. Remove bolts (18). Remove bolt (19) and lock (20). Remove adjusting ring (21) and remove bearing cup (22).


    Illustration 15g01413403


    Illustration 16g01413406

  17. Attach Tooling (K) in order to separate the cover from the differential housing.

  18. Remove Tooling (K) and attach Tooling (L) and a suitable lifting device to cover (23). The weight of cover (23) is approximately 79 kg (175 lb).

  19. Remove cover (23).


    Illustration 17g01413413


    Illustration 18g01413414

  20. Remove bolts (24). Attach Tooling (E) and a suitable lifting device to differential assembly (25). The weight of differential assembly (25) is approximately 181 kg (400 lb).

  21. Remove differential assembly (25). Position differential assembly (25) onto a suitable work surface.


    Illustration 19g01413391

  22. Use Tooling (M) in order to remove bearing cone (26) from each side of differential assembly (25).


    Illustration 20g01413394

  23. Put an alignment mark on housing (27) and differential assembly (25) for assembly purposes. Position a suitable lifting device around the differential, as shown.

  24. Remove bolts (28), the locknuts, and the washers that hold housing (27) to differential assembly (25). Remove housing (27) and the differential bevel gear from differential assembly (25). The weight of housing (27) and the differential bevel gear is approximately 82 kg (180 lb).


    Illustration 21g01413435

  25. Remove bolts (29) and housing (27) from differential bevel gear (30). The weight of housing (27) is approximately 41 kg (90 lb). The weight of differential bevel gear (30 ) is approximately 41 kg (90 lb).


    Illustration 22g01413451

  26. Remove thrust washer (31) and differential pinion gear (32).


    Illustration 23g01413454

  27. Position a suitable lifting sling around differential spider (34). Remove differential spider (34) and differential pinion assemblies (33) as an assembly from differential assembly (25). The weight of differential spider (34) and differential pinion assemblies (33) is approximately 36 kg (80 lb).


    Illustration 24g01413466

  28. Remove differential pinion assemblies (33) from differential spider (34).

  29. Use the following procedure in order to disassemble the pinion assembly:


      Illustration 25g01413477

    1. Position Tooling (N) in a suitable vise. Install differential pinion assembly (33) onto Tooling (N), as shown.

      Note: Be sure that Groove (X) is in alignment with Dowel (Y).



      Illustration 26g01413489

    2. Install the nut onto the shaft for Tooling (N) at this time.


      Illustration 27g01413508


      Illustration 28g01413820

    3. Use a hammer and a brass drift in order to bend the tabs on nut lock (35).

    4. Use Tooling (P) to remove nut (36) (not shown). Remove the nut from the shaft on Tooling (N).


      Illustration 29g01413821

    5. Remove nut lock (35).


      Illustration 30g01413823


      Illustration 31g01413824

    6. Remove differential pinion assembly (33) and bearing cone (37). Remove bearing cups (38) from differential pinion assembly (33).


      Illustration 32g01413836

    7. Remove retainer (39) and bearing cone (40) from Tooling (N).

  30. Repeat the procedure in Step 29 for the remaining pinion assemblies.


    Illustration 33g01413840

  31. Remove the remaining differential bevel gear (31) and thrust washer (32) from differential housing assembly (25).

  32. Remove bolts (28).


    Illustration 34g01414302

    Note: Mark the position of adjusting ring (41) for assembly purposes.

  33. Remove bolt (43) and lock (42). Remove adjusting ring (41) and remove bearing cup (44) from the differential housing.

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