424B and 424B HD Backhoe Loaders Power Train Caterpillar

Assembly Procedure

Note: The transmission will be assembled in major components. The major components will then be assembled.

Note: Cleanliness is an important factor. Before assembly, all parts should be cleaned thoroughly 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 which may cause later trouble. Inspect all parts. If any parts are worn or damaged, use new parts for replacement.

1. Apply a light film of clean transmission oil to all components before assembly.

Transmission Case

Illustration 1	g00729262

Note: Install the shims behind each bearing cup that was recorded on the disassembly procedure.

1. Install bearing cups (60), (61), (62), (63), and (64).

(Direct Drive) Input Shaft

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Illustration 2	g00731364

1. Install the needle thrust bearings on the shafts. The open end of cups (1) must point away from the bearings or gears that are contacted
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   Illustration 3	g00729745

2. Install the seals on piston (56).
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   Illustration 4	g03230797

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

3. Install piston (56). Install the retainer and spring (55). Use Tooling (A) and a suitable press to compress spring (55). Install retaining ring (54).
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   Illustration 5	g00729210

4. Install clutch pack (53) and retainer (52).

5. Repeat Steps 2 through 4 for the opposite end of the input shaft.
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   Illustration 6	g00729208

6. Install gear (51), needle bearing (50), and spacer (49). Install retaining ring (48).
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   Illustration 7	g03230816

7. Heat bearing cone (47) to 135° C (275° F). Install bearing cone (47).

8. Install the input shaft.

(Direct Drive) Reverse Shaft

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Illustration 8	g00729785

1. Heat bearing cones (45) and (46) to 135° C (275° F). Install bearing cones (45) and (46).

2. Install the reverse shaft.

(Direct Drive) Shaft

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Illustration 9	g00729792

1. Heat bearing cones (43) and (44) to 135° C (275° F). Install bearing cones (43) and (44).

2. Install the shaft.

(Direct Drive) Output Shaft (Rear)

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Illustration 10	g00729806

1. Install gear (42).
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   Illustration 11	g00729200

2. Install housing (41) and gear (40). Install retaining ring (39).
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   Illustration 12	g00729810

3. Install synchronizer (38). Install gear (37). Heat bearing cone (36) to 135° C (275° F). Install bearing cone (36).
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   Illustration 13	g00729198

4. Install synchronizer (35), spacer (34), and bearings (33).
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   Illustration 14	g00729812

5. Install gear (31) and (32). Heat bearing cone (30) to 135° C (275° F). Install bearing cone (30).

6. Install the output shaft (rear) in the transmission.
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   Illustration 15	g03652350

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   Illustration 16	g00729064

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

7. Install two gearshift rods (23) on shift forks (29). Install the gearshift rods in the transmission. Install three balls (28), two springs (27), and O-ring seal (26). Install plug (25). Tighten plug (25) to a torque of 35 ± 5 N·m (26 ± 4 lb ft).
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   Illustration 17	g00729062

8. Install screws (24) on each of the gearshift rods (23).

(Direct Drive) Output Shaft (Front)

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Illustration 18	g00729861

1. Install seals on piston (22).
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   Illustration 19	g00729879

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   Illustration 20	g03230838

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   Improper assembly of parts that are spring loaded can cause bodily injury. To prevent possible injury, follow the established assembly procedure and wear protective equipment.

2. Install spring (19) and retainer (21).

3. Use Tooling (B) and a suitable press to compress spring (19). Install retaining ring (20).
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   Illustration 21	g00728948

4. Install clutch pack (18) and retainer (17).
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   Illustration 22	g00728945

5. Install thrust washer (16), needle bearing (15), spacer (14), and two roller bearings (13).
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   Illustration 23	g00729892

6. Heat bearing cone (11) to 135° C (275° F). Install bearing cone (11).
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   Illustration 24	g00729903

7. Heat bearing cone (10) to 135° C (275° F). Install bearing cone (10).
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   Illustration 25	g00728940

8. Install front output shaft (9).

Final Assembly

Illustration 26	g03230841

Note: Clean the mating surfaces of case (7). Apply Tooling (G) to the mating surface of the case.

1. Attach Tooling (C) to case (7). Attach a suitable lifting device to Tooling (C). The weight of case (7) is approximately 38 kg (84 lb). Use 14 bolts (8). Install case (7). Tighten bolts (8) to a torque of 55 ± 10 N·m (41 ± 7 lb ft).
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   Illustration 27	g03230843

2. Install a bolt in the output shaft. The output shaft must be seated fully. Install Tooling (D), as shown. Zero Tooling (D). Pry up on the bolt and record the reading on Tooling (D). The reading must be 0.055 ± 0.025 mm (0.0022 ± 0.0009 inch). Add or remove shims in Step 1 in the Case Assembly Procedure to obtain the correct reading.
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   Illustration 28	g00730086

3. Repeat Step 1 for the input shaft and the output shaft (front). Use the same tolerance for all of the shafts. Remove the expansion plug to check the input shaft. Use a screwdriver to pry up on the input shaft. Install a new Expansion Plug.
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   Illustration 29	g00728906

4. Install yoke (4), washer (5), and bolt (6). Tighten bolt (6) to a torque of 100 ± 20 N·m (74 ± 15 lb ft).
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   Illustration 30	g00728902

5. Install plug (3). Tighten plug (3) to a torque of 47 ± 7 N·m (35 ± 5 lb ft).
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   Illustration 31	g00728895

6. Install Implement pump drive shaft (2) in transmission (1).
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   Illustration 32	g03230847

7. Remove transmission (1) from Tooling (E). The weight of transmission (1) is approximately 200 kg (441 lb).

End By:

1. Install the transmission.