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416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Power Train Caterpillar


Transmission (Power Shift) - Disassemble

Usage:

416D B2D

Disassembly Procedure

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Table 1
Required Tools    
Tool     Part Number     Part Description     Qty    
A     1U-7502     Repair Stand     1    
B     152-7085  (1)     Transmission Shaft Handler     1    
189-0409 Shackle As     1    
C     1P-0074     Slide Hammer     1    
D     8H-0063     Bearing Puller Assembly     1    
6V-3010 Puller Group     1    
126-7177 Leg     2    
E     1U-6405     Puller     1    
F     152-7055     Spring Compressor     1    
G     1U-6400     Puller     1    
H     128-5041     Bearing Puller     1    
6V-3010 Puller Group     1    
126-7177 Leg     2    
I     6V-2157     Link Bracket     1    
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( 1 ) CE Compliant

Start By:

  1. Remove the transmission. Refer to Disassembly and Assembly, "Transmission (Powershift) - Remove".

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NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.

Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the component should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism.

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

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    Illustration 1g00730318

  1. Use a suitable lifting device in order to install transmission (1) on tooling (A) . The weight of transmission (1) is 172 kg (379 lb).
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    Illustration 2g00730319

  1. Remove two valve groups (2) .
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    Illustration 3g00730320

  1. Remove nut (3) , washer (4) , and coil assembly (5) . Remove seal kit (6) from cartridge (7) .
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    Illustration 4g00730321

  1. Remove magnetic sensor (8) .
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    Illustration 5g00730322
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    Illustration 6g00730323

  1. Remove tube assembly (9) .
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    Illustration 7g00730324

  1. Remove valve group (10) .
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    Illustration 8g00730325

  1. Remove O-ring (11) and O-ring (12) .
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    Illustration 9g00730326

  1. Remove valve group (13) .
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    Illustration 10g00730327

  1. Remove two O-rings (14) and O-ring (15) .
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    Illustration 11g00730328

  1. Remove two bolts (16) and plate (17) .
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    Illustration 12g00730329

  1. Remove O-ring (18) .
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    Illustration 13g00730330

  1. Remove screen filter (19) .
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    Illustration 14g00730331

  1. Remove oil filter (20) .
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    Illustration 15g00730333

  1. Remove two bolts (21) and elbow assembly (22) .
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    Illustration 16g00730334

  1. Remove two O-rings (23) .
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    Illustration 17g00730336

  1. Remove valve group (24) .
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    Illustration 18g00730337

  1. Remove ball (25) , spring (26) , and O-ring (27) .
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    Illustration 19g00730338

  1. Remove pump drive shaft (28) from the transmission.
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    Illustration 20g00730340

  1. Remove bolt (29) , washer (30) , and yoke assembly (31) from the output shaft.
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    Illustration 21g00730342

  1. Remove gasket (32) from yoke (33) .
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    Illustration 22g00730343

  1. Remove bolt (34) and washer (35) .
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    Illustration 23g00730344

  1. Remove O-ring (36) and yoke (37) from the output shaft.
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    Illustration 24g00730345

  1. Remove four bolts (38) , washers (39) , and pump group (40) .
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    Illustration 25g00730348

  1. Remove seal (41) .
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    Illustration 26g00730349

  1. Remove lip seal (42) from pump group (40) .
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    Illustration 27g00730350

  1. Use tooling (I) and a suitable lifting device in order to support the transmission case. Remove eighteen bolts (43) .
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    Illustration 28g00730351

  1. Use a pry bar in the slots of the transmission case in order to break the seal. Carefully remove case assembly (44) . The weight of case assembly (44) is 26.9 kg (59 lb).
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    Illustration 29g00730353

  1. Remove lip seal (45) from case assembly (44) .
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    Illustration 30g00730354

  1. Remove tube assembly (46) and (47) from case assembly (44) .
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    Illustration 31g00730355

  1. Remove bearing cups (48) , (49) , and (50) from case assembly (44) .
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    Illustration 32g00730356

    Note: Record the measurement of shims (51) to aid in installation.

  1. Remove shims (51) from case (44) .
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    Illustration 33g00730357

  1. Remove output shaft (52) .
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    Illustration 34g01280623

  1. Use Tooling (B) , washer (35) , and bolt (34) in order to remove rear output shaft (53) , shaft (54) , and input shaft (55) . The combined weight of rear output shaft (53) , shaft (54) , and input shaft (55) is 61.3 kg (135 lb).
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    Illustration 35g00730359

  1. Remove reverse shaft (56) from the case assembly.
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    Illustration 36g00730360

  1. Use tooling (C) in order to remove bearing cups (57) .
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    Illustration 37g00730362

  1. Remove lip seal (58) from the case assembly.
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    Illustration 38g00730363

  1. Remove tube assembly (59) .

Output Shaft (Front)

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    Illustration 39g00730365

  1. Remove ring (60) from front output shaft (52) .
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    Illustration 40g00730366

  1. Use tooling (D) in order to remove bearing cone (61) .
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    Illustration 41g00730368
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    Illustration 42g00730369

  1. Use tooling (E) in order to remove spacer (62) , bearing cone (63) , washer (64) , needle thrust bearing (65) , and gear (66) .
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    Illustration 43g00730370

  1. Remove caged roller bearing (67) , spacer (68) , caged roller bearing (69) , needle thrust bearing (70) , and washer (71) .
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    Illustration 44g00730371

  1. Remove retaining ring (72) and end plate (73) .
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    Illustration 45g00730372

  1. Remove eight friction discs (74) and eight plates (75) .
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    Illustration 46g00730375

  1. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (76) .
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    Illustration 47g00730376

  1. Remove spring assembly (77) .
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    Illustration 48g00730378

  1. Use shop air in order to remove piston assembly (79) , as shown.
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    Illustration 49g00730379

  1. Remove ring (78) and the O-ring from piston (79) .

Output Shaft (Rear)

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    Illustration 50g00730381

  1. Remove rings (80) and (81) .
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    Illustration 51g00730382
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    Illustration 52g00730553

  1. Use tooling (G) in order to remove bearing cone (82) , washer (83) , needle thrust bearing (84) , caged roller bearing (85) , and gear (86) .
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    Illustration 53g00730554

  1. Remove caged roller bearing (87) , needle thrust bearing (88) , and washer (89) .
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    Illustration 54g00730555

  1. Remove retaining ring (90) and end plate (91) .
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    Illustration 55g00730556

  1. Remove eight friction discs (92) and eight plates (93) .
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    Illustration 56g00730557

  1. Use tool (F) in order to compress the spring assembly. Remove retaining ring (94) .
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    Illustration 57g00730558

  1. Remove spring assembly (95) .
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    Illustration 58g00730559

  1. Use shop air in order to remove piston assembly (96) .
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    Illustration 59g00730560

  1. Remove seal (97) and the O-ring from piston (98) .
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    Illustration 60g00730564

  1. Use tooling (H) in order to remove bearing cone (99) .
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    Illustration 61g00730566

  1. Use tooling (E) in order to remove gear (100) .
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    Illustration 62g00730568

  1. Remove washer (101) and needle thrust bearing (102) .
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    Illustration 63g00730569

  1. Remove gear (103) from the output shaft (rear).
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    Illustration 64g00730578

  1. Remove caged roller bearing (104) , spacer (105) , caged roller bearing (106) , needle thrust bearing (107) , and washer (108) .
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    Illustration 65g00730581

  1. Remove retaining ring (109) and end plate (110) .
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    Illustration 66g00730584

  1. Remove eight friction discs (111) and eight plates (112) .
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    Illustration 67g00730585

  1. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (113) .
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    Illustration 68g00730586

  1. Remove spring assembly (114) .
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    Illustration 69g00730588

  1. Use shop air in order to remove piston (116) , as shown.
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    Illustration 70g00730589

  1. Remove seal (115) and the O-ring from piston (116) .

Shaft

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    Illustration 71g00730590

  1. Remove bolt (118) and washer (119) .
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    Illustration 72g00730737

  1. Use tooling (H) in order to remove bearing cone (120) .
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    Illustration 73g00730738

  1. Use tooling (G) in order to remove gears (121) and (122) .
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    Illustration 74g00730740

  1. Remove two rings (123) .
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    Illustration 75g00730741

  1. Use tooling (H) in order to remove bearing cone (124) .
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    Illustration 76g00730742

  1. Remove washer (125) and needle thrust bearing (126) .
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    Illustration 77g00730743

  1. Remove gear (127) .
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    Illustration 78g00730745

  1. Remove caged roller bearing (128) , caged roller bearing (129) , needle thrust bearing (130) , and washer (131) .
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    Illustration 79g00730746

  1. Remove retaining ring (132) and end plate (133) .
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    Illustration 80g00730748

  1. Remove eight friction discs (134) and eight plates (135) .
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    Illustration 81g00730749

  1. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (136) .
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    Illustration 82g00730750

  1. Remove spring assembly (137) .
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    Illustration 83g00730751

  1. Use shop air in order to remove piston assembly (139) .
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    Illustration 84g00730752

  1. Remove seal (138) and the O-ring from piston (139) .

Input Shaft

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    Illustration 85g00730754

  1. Remove four rings (141) from input shaft (55) .
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    Illustration 86g00730756

  1. Use tooling (D) in order to remove bearing cone (142) .
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    Illustration 87g00730757

  1. Remove retaining ring (143) .
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    Illustration 88g00730758

  1. Remove washer (144) , needle thrust bearing (145) , and gear (146) .
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    Illustration 89g00730760

  1. Remove caged roller bearing (147) , spacer (148) , caged roller bearing (149) , needle thrust bearing (150) , and washer (151) .
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    Illustration 90g00730762

  1. Remove retaining ring (152) and end plate (153) .
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    Illustration 91g00730764

  1. Remove eight friction discs (154) and eight plates (155) .
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    Illustration 92g00730796

  1. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (156) .
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    Illustration 93g00730797

  1. Remove spring assembly (157) .
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    Illustration 94g00730799

  1. Use shop air in order to remove piston assembly (158) .
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    Illustration 95g00730839

  1. Remove seal (159) and the O-ring from piston (160) .
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    Illustration 96g00730842

  1. Remove ring (161) .
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    Illustration 97g00730844

  1. Use tooling (H) in order to remove bearing cone (162) .
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    Illustration 98g00730845

  1. Remove washer (163) and needle thrust bearing (164) .
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    Illustration 99g00730846

  1. Remove gear (165) .
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    Illustration 100g00730848

  1. Remove caged roller bearing (166) , caged roller bearing (167) , needle thrust bearing (168) , and washer (169) .
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    Illustration 101g00730850

  1. Remove retaining ring (170) and end plate (171) .
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    Illustration 102g00730853

  1. Remove eight friction discs (172) and eight plates (173) .
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    Illustration 103g00730854

  1. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (174) .
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    Illustration 104g00730863

  1. Remove spring assembly (175) .
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    Illustration 105g00730865

  1. Use shop air in order to remove piston (177) .
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    Illustration 106g00730867

  1. Remove seal (176) and the O-ring from piston (177) .

Reverse Shaft

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    Illustration 107g00730868

  1. Remove two rings (179) from reverse shaft (56) .
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    Illustration 108g00730870
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    Illustration 109g00730936

  1. Use tooling (E) in order to remove bearing cone (180) , washer (181) , needle thrust bearing (182) , caged roller bearing (183) , and gear (184) .
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    Illustration 110g00730937

  1. Remove caged roller bearing (185) , needle thrust bearing (186) , and washer (187) .
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    Illustration 111g00730938

  1. Remove retaining ring (188) and end plate (189) .
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    Illustration 112g00730939

  1. Remove eight friction discs (190) and eight plates (191) .
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    Illustration 113g00730940

  1. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (192) .
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    Illustration 114g00730941

  1. Remove spring assembly (193) .
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    Illustration 115g00730942

  1. Use shop air in order to remove piston assembly (194) .
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    Illustration 116g00730943

  1. Remove seal (195) and the O-ring from piston (196) .
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    Illustration 117g00730944

  1. Use tooling (D) in order to remove bearing cone (197) .

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