IDLER GP-FRONT 2394321 - Caterpillar

Start By:a. separation of transmission from transfer gears (see DISASSEMBLE TRANSMISSION)1. Fasten a hoist and turn the transfer gears over. Put the transfer gears on blocks with the back of the case up as shown. The weight of the unit is 279 kg (615 lb.). 2. Remove plates (2), cover (1) and the gasket from the back of the bearing cage. 3. Remove bolts (3) and use two 3/8"-16 NC forcing screws to loosen bearing cage (4) from the case. 4. Remove bearing cage (4) from the case.5. Remove O-ring seal (6) and bearing cup (5) from bearing cage (4). 6. Remove shims (8) from the case. Keep the shims together for assembly purposes.7. Fasten a hoist and remove gear (7) and the bearing cones from the case. The weight of the gear is 27 kg (60 lb.). 8. Use tooling (A) to remove the bearing cones from each side of gear (7). 9. Remove bearing cup (9) from the case.10. Fasten a hoist and put the transfer gear case in a vertical position. The weight of the unit is now 240 kg (530 lb.). 11. Remove the nuts and bearing cage (10) from the case. 12. Remove seal (11) from the bearing cage. 13. Remove O-ring seal (13) and bearing cup (12) from the bearing cage. 14. Remove spacer (14) from the end of the output shaft.15. Remove the bolt, retainer, O-ring seal and yoke assembly from the output shaft. 16. Remove seal retainer (15) and the O-ring seal from the bearing cage. 17. Remove seal (16) from retainer (15). 18. Install two 3/8"-16 NC guide bolts in the case through bearing cage (17) as shown. 19. Fasten a nylon strap and hoist to hold gear (18) in position. Use a soft faced hammer and push output shaft (20) out of bearing and gear (18). Remove bearing (19). Remove shaft (20) and cage (17) as a unit from the opposite side of the transfer gear case. 20. Remove O-ring seal (21) from cage (17). 21. Use a press and push shaft (20) out of bearing cage (17). 22. Use tool group (B) and a press to push the bearings out of cage (17). 23. Remove gear (18) from the transfer gear case. 24. Remove covers (23) and the gasket from each side of the transfer gear case if necessary.25. Remove cover assembly (22) from the transfer gear case. 26. Remove tube assembly (25) and screen (24) from the transfer gear case.Assemble Transfer Gears
1. Install covers (23) and the gaskets on each side of the transfer gear case.2. Make sure the magnets on the tube assembly and the screen are clean and free of dirt and foreign material.3. Install tube assembly (25) and screen (24) in the transfer gear case. 4. Install the O-ring seal in cover assembly (22) and put clean power train oil on it. Install cover assembly (22). 5. Put gear (18) in position in the transfer gear case. Fasten a hoist to hold the