30596 Mercury STARTER PAWL

Start By:a. remove radiator guard and radiatorb. remove air cleaner elements and housingc. remove center drive shaft *d. remove rear drive shaft **These operations are in the Power Train Disassembly & Assembly module, Form No. SENR6667. 1. Put identification marks on the seven wires that are connected to the electric starting motor for installation purposes. Disconnect six wires (1) from the electric starting motor. Disconnect connector (2).2. Disconnect clip (3) for the ground wire at the oil pan.3. Disconnect four wires (4) from the ground located next to the master disconnect switch. 4. Close the two shut-off valves for the heater. Disconnect two heater hoses (5) from the shut-off valves at the water pump.
Regulations prohibit the venting of any refrigerant into the atmosphere. Refer to Caterpillar publication SENR3334-01 and NEDG5065-01 for the proper procedure, equipment and tools to reclaim refrigerant from any Caterpillar machine.Always wear goggles when working on air conditioning systems. The system is under pressure at all times, engine running or not. Escaping refrigerant - 12 (CCl2F2 Dichlorodifluoromethane) can cause freezing of human flesh.Do not smoke while working on air conditioning systems. INHALING refrigerant -12 THROUGH ANY SMOKING MATERIAL, ALTHOUGH NOT TOXIC OR FLAMMABLE, CAN GENERATE LETHAL PHOSGENE GAS AND CAUSE VIOLENT ILLNESS OR DEATH. ALSO, HEAT MUST NEVER BE APPLIED TO A CHARGED SYSTEM. See Air Conditioning And Heating Service Manual, Form No. SENR3334-01, for more information on removal and installation of lines and refrigerant from the system.
5. Disconnect hose assemblies (6) from the air conditioner compressor.6. Disconnect governor control cable (7). 7. Disconnect connector (9). 8. Remove bolt and clamp (8). Reposition two tube assemblies (10). 9. Remove the bolts and washers that hold relay panel (11) in position. Move the relay panel clear of the engine.10. Remove the harness supports from wiring harness (12).11. Remove the bolts and washers that hold right hand engine enclosure door (13). Remove the right hand engine enclosure door. Remove the left hand engine enclosure door.12. Disconnect all electrical connectors. 13. Remove windshield washer reservoir (14). 14. Fasten tool (A) and a hoist to firewall group (15) as shown.15. Disconnect the two hose assemblies from each side of firewall group.16. Remove the bolts and washers that hold the firewall group in position.
Be sure all wires, hose assemblies and mounting hardware have been removed prior to removal of the firewall group.
17. Remove firewall group (15). The weight of the firewall group is approximately 125 kg (275 lb). 18. Remove two bolts (20) and the washers that hold transmission oil level gauge guide tube (19) to the transfer gear case.19. Remove two bolts (18) and the washers that hold transmission oil filler tube (16) to the transfer gear case.20. Remove two bolts (17) and the washers that hold the clip for the transmission oil level gauge guide tube to the fuel tank. Remove the transmission oil level gauge guide tube and the transmission oil filler tube. Remove the gaskets with each tube. 21. Remove eight bolts (22) and the washers that hold two hoses (21) to the supplemental steering pump. Remove the hoses from the pump. 22. Remove the six bolts and washers that hold seat assembly (23) in position. Using two persons, remove the seat assembly from the cab. The weight of the seat assembly is approximately 23 kg (50 lb). Remove plate (24) located directly under the seat assembly. 23. Put identification marks on six hose assemblies (25) that are connected to the hydraulic pump for implement, steering and pilot systems. Disconnect the six hose assemblies from the hydraulic pump. The large oil supply hose which is routed between the hydraulic pump and the hydraulic oil tank should also be disconnected at the hydraulic oil tank and removed from the machine.24. Disconnect one connector (26). 25. Disconnect wiring harness (28) for the transmission hydraulic controls.26. Remove all wiring harness supports (27). 27. Disconnect two fuel lines (30) at the side of the transmission case.28. Disconnect hose assembly (29) from the side of the transmission case. 29. Disconnect hose (31) from the torque converter. 30. Disconnect two connectors (32).31. Disconnect one clamp (33), and move wiring harness (34) to the opposite side of the engine. 32. Remove bolt (35) and the clip that holds the wiring harness to the backside of the transfer gear case. Disconnect connector (36). 33. Fasten tool (B) to the threaded bolt hole in the top of the torque converter as shown.34. Support the engine,