416D, 420D, 424D, 428D, 432D and 442D Backhoe Loaders Transmission (Autoshift) Caterpillar

All Wheel Drive

Illustration 1	g00808275
(1) Input shaft (2) Forward high output gear (3) Forward high clutch pack (4) Forward high clutch piston (5) Reverse input gear (6) Reverse clutch piston (7) Reverse clutch pack (8) Reverse output gear (9) Reverse shaft (10) Forward low clutch pack (11) Forward low clutch piston (12) Forward low output gear (13) Input gear (14) Clutch pack for clutch 1 (15) Clutch piston for clutch 1 (16) Output gear for clutch 1 (17) Countershaft (18) Gear (19) Gear (20) Clutch pack for clutch 2 (21) Clutch piston for clutch 2 (22) Front output shaft (23) Clutch piston for the front output shaft (24) Clutch pack for the front output shaft (25) Gear (26) Gear (27) Gear (28) Rear output shaft (29) Clutch piston for clutch 3 (30) Clutch pack for clutch 3 (31) Gear (32) Gear (33) Gear

The transmission has the following features: five speed in forward, three-speed in reverse, constant mesh and countershaft transmission. The transmission contains electrical solenoids in order to shift from forward direction to the reverse direction. The transmission will shift from first through fifth gears. Fifth gear is automatically engaged from fourth gear when the engine speed reaches high idle.

The transmission has the following shafts: input shaft (1), reverse shaft (9), countershaft (17), rear output shaft (28) and front output shaft (22) .

The input shaft (1) contains the forward high clutch and the forward low clutch. The reverse shaft (9) contains the reverse clutch. The countershaft (17) contains clutch 1. The rear output shaft (23) contains clutch 2 and clutch 3. The front output shaft (22) contains the all wheel drive clutch. The all wheel drive clutch is referred to as the clutch for the front output shaft.

A speed clutch and a direction clutch must be engaged in order to send power through the transmission. The speed and direction of the machine must be selected manually by the operator.

Illustration 2	g00733821

The autoshift switch is located on the right side of the dash on the machine. The control is used to select either manual shift (2) or automatic shift (1). The automatic mode allows the transmission to select a gear when the engine speed and the operating conditions are correct. When you are in the manual mode the transmission stays in the selected gear on the transmission control lever.

The chart gives the combination of the solenoids that are energized and the clutches that are engaged for each FORWARD speed and each REVERSE speed.

Illustration 3	g00758903
(34) Solenoid for clutch 2 (35) Solenoid for clutch 3 (36) Reverse solenoid (37) Forward low solenoid (38) Forward high solenoid

Illustration 4	g00807862
(39) Solenoid for the all wheel drive (40) Solenoid for clutch 1

The operator changes the direction of the machine manually by the transmission control lever. The transmission will automatically shift up to the highest speed that is selected on the transmission control lever. The transmission control lever is a dual function lever. The gear selection is made by twisting the lever. The FORWARD selection is made by moving the lever up. The REVERSE selection is made by moving the lever down.

The switches that are in the transmission control lever activate the electronic transmission control. The electronic transmission control executes the speed that is selected and the direction that is selected by the operator. The electronic transmission control energizes the solenoids for the transmission in order to engage the correct clutches for the direction and speed that is selected.

The electronic transmission control is located on the right side of the machine in the battery box.

The operator moves the transmission direction switch and the speed control in order to move the machine. The clutch engagement is done through an electrical harness that is connected to the electronic transmission control to the solenoids on the transmission.

The input shaft (1) sends the power from the torque converter turbine to the forward low clutch and to the forward high clutch. The input shaft rotates the same direction as the flywheel. Therefore, the plates also rotate in the same direction and at the same speed as the input shaft.

The input shaft contains two internal oil passages. The internal oil passages are for lubrication and cooling of the clutch piston and for the engagement of the clutch packs.

FORWARD HIGH output gear (2) and FORWARD LOW output gear (12) are free to rotate on input shaft (1) when the clutch pack for FORWARD HIGH (3) or the clutch pack for FORWARD LOW (10) is not engaged. The discs rotate with the output gears.

Reverse shaft (9) and gears (5) and (8) provide reverse rotation to countershaft (17) when the reverse clutch is engaged. Reverse gear (8) is meshed with gear (13). The power flows from the reverse gear (8) to gear (13) when reverse clutch pack (7) is engaged.

Countershaft (17) transfers power to the speed range gears on the rear output shaft (28). This depends on the clutch pack that is engaged.

The transmission neutralizer switch is located on either the left side of the dash or on the loader control lever. When you activate the transmission neutralizer switch on the dash, all of the direction clutches are released and the transmission is placed in NEUTRAL. The neutralizer switch that is on the loader control lever disengages the solenoids for the direction control.

Power Flow (First Speed Forward)

Illustration 5	g00807875
Power flow in first speed forward (1) Input shaft (2) Forward low clutch pack (3) Forward low output gear (4) Input gear (5) Clutch pack for clutch 1 (6) Output gear for clutch 1 (7) Countershaft (8) Gear (9) Rear output shaft (10) Clutch piston for the front output shaft (11) Clutch pack for the front output shaft (12) Front output shaft (13) Gear (14) Gear

Illustration 6	g00807892
(15) Solenoid for clutch 1 (16) All wheel drive solenoid (17) Forward low solenoid

When the transmission is in FIRST SPEED FORWARD, the solenoid for FORWARD LOW (17) engages the FORWARD LOW clutch (2) and the solenoid for clutch 1 (15) engages the clutch pack for clutch 1 (5). The all wheel drive solenoid (16) engages the clutch pack for the front output shaft (11) .

Torque from the engine is transferred through the torque converter to the input shaft (1). When the FORWARD LOW clutch pack (2) engages, the clutch pack causes the gear (3) to rotate. Gear (3) turns gear (4) on countershaft (7). When the clutch pack for clutch 1 (5) engages, the clutch pack causes gear (6) to rotate. Gear (6) drives gear (8) on the rear output shaft (9). Gear (8) is splined to the rear output shaft (9) .

Gear (14) is welded to the rear output shaft (9). Gear (8) turns the rear output shaft and gear (14). Gear (14) turns gear (13) on the front front output shaft (12). Gear (13) is splined to the clutch for the front output shaft (11). When the clutch pack for the front output shaft (11) engages, the clutch pack turns the front output shaft (12) .

Power Flow (Second Speed Forward)

Illustration 7	g00807905
Power flow in second speed forward (1) Input shaft (2) Forward high output gear (3) Forward high clutch pack (4) Clutch pack for clutch 1 (5) Output gear for clutch 1 (6) Countershaft (7) Gear (8) Rear output shaft (9) Clutch pack for the front output shaft (10) Front output shaft (11) Gear (12) Gear (13) Gear

Illustration 8	g00759050
(14) Solenoid for clutch 1 (15) Clutch solenoid for the all wheel drive

Illustration 9	g00759051
(16) Forward high solenoid

When the transmission is in SECOND SPEED FORWARD, the solenoid for FORWARD HIGH (16) engages the FORWARD HIGH clutch (3) and the solenoid for clutch 1 (14) engages the clutch pack for clutch 1 (4). The all wheel drive solenoid (15) engages the clutch pack for the front output shaft (9) .

Torque from the engine is transferred through the torque converter to the input shaft (1). When the FORWARD HIGH clutch pack (3) engages, the clutch pack causes the forward high output gear (2) to turn. The forward high output gear turns the gear (13) on countershaft (6). Gear (13) is splined to countershaft (6). Gear (13) turns the countershaft. When the clutch pack for clutch 1 (4) engages, the clutch pack causes output gear (5) to turn. output gear (5) turns gear (7) on the rear output shaft (8). Gear (7) is splined to rear output shaft (8). Gear (7) turns the rear output shaft .

Gear (12) is welded to the rear output shaft (8). Gear (7) turns gear (12). Gear (12) turns gear (11) on the front output shaft (10). Gear (11) is splined to the clutch pack for the front output shaft (9). When the clutch pack for the front output shaft is engaged, the clutch pack turns the front output shaft.

Power Flow (Third Speed Forward)

Illustration 10	g00807914
Power flow in third speed forward (1) Input shaft (2) Forward low clutch pack (3) Forward low output gear (4) Gear (5) Clutch pack for clutch 2 (6) Countershaft (7) Gear (8) Rear output shaft (9) Clutch pack for the front output shaft (10) Clutch piston for the front output shaft (11) Front output shaft (12) Gear (13) Gear (14) Gear

Illustration 11	g00807929
(15) Solenoid for clutch 2 (16) Forward low solenoid

Illustration 12	g00807930
(17) All wheel drive solenoid

When the transmission is in THIRD SPEED FORWARD, the solenoid for FORWARD LOW (16) engages the FORWARD LOW clutch pack (2) and the solenoid for clutch 2 (14) engages the clutch pack for clutch 2 (5). The all wheel drive solenoid (16) engages the clutch pack for the front output shaft (9) .

Torque from the engine is transferred through the torque converter to the input shaft (1). When the FORWARD LOW clutch pack (2) engages, the clutch pack causes the output gear (3) to turn. The output gear (3) is splined to the clutch pack. Output gear (3) turns gear (4) on the countershaft (6). Gear (4) is welded to the countershaft. Gear (14) is part of the countershaft. Gear (4) turns gear (14).

Gear (14) turns gear (7). Gear (7) is splined to the clutch pack for clutch 2. When the clutch pack for clutch 2 is engaged, gear (7) turns the rear output shaft (8). Gear (13) is welded to the rear output shaft (8). Gear (13) turns gear (12). Gear (12) is splined to the clutch pack for the front output shaft (9). When the clutch for the front output shaft (9) engages, the clutch turns the front output shaft (11) .

Power Flow (Fourth Speed Forward)

Illustration 13	g00807939
Power flow in fourth speed forward (1) Input shaft (2) Forward high output gear (3) Forward high clutch pack (4) Gear (5) Countershaft (6) Rear output shaft (7) Gear (8) Clutch pack for clutch 2 (9) Clutch pack for the front output shaft (10) Front output shaft (11) Gear (12) Gear (13) Gear

Illustration 14	g00759081
(14) Forward high clutch solenoid (15) Solenoid for clutch 2

Illustration 15	g00759087
(16) All wheel drive solenoid

When the transmission is in FOURTH SPEED FORWARD, the solenoid for FORWARD HIGH (14) engages the FORWARD HIGH clutch (3) and the solenoid for clutch 2 (15) engages the clutch pack for clutch 2 (8). The all wheel drive solenoid (16) engages the clutch pack for the front output shaft (9) .

Torque from the engine is transferred through the torque converter to the input shaft (1). When the FORWARD HIGH clutch (3) engages, the clutch turns the gear (2). The gear is splined to the clutch (3). Gear (2) turns the gear (13) on countershaft (5). Gear (13) is splined to the countershaft. Gear (13) turns the countershaft. Gear (4) is part of the countershaft. Gear (4) turns gear (7) on the rear output shaft (6) .

Gear (7) is splined to the clutch pack for clutch 2 (8). When the clutch pack for clutch 2 engages, the gear (7) turns the rear output shaft (6). Gear (12) is welded to the rear output shaft. Gear (7) turns gear (12). Gear (12) turns gear (11) on the front output shaft (10) .

Gear (11) is splined to the clutch pack for the front output shaft (9). When the clutch for the front output shaft (9) engages, the clutch turns the front output shaft (10) .

Power Flows (Fifth Speed Forward)

Illustration 16	g00807952
Power flow in fifth speed forward (1) Input shaft (2) Forward high output gear (3) Forward high clutch pack (4) Gear (5) Countershaft (6) Rear output shaft (7) Gear (8) Clutch pack for the front output shaft (9) Front output shaft (10) Gear (11) Clutch pack for clutch 3 (12) Gear (13) Gear (14) Gear (15) Gear

Illustration 17	g00807960
(16) Forward high solenoid (17) Solenoid for clutch 3

Illustration 18	g00807961
(18) Speed sensor (19) All wheel drive solenoid

When the transmission is in FIFTH SPEED FORWARD, the solenoid for FORWARD HIGH (16) engages the FORWARD HIGH clutch pack (3) and the solenoid for clutch 3 (17) engages the clutch pack for clutch 3 (11). The all wheel drive solenoid (17) engages the clutch pack for the front output shaft (8) .

Torque from the engine is transferred through the torque converter to the input shaft (1). When the FORWARD HIGH clutch pack (3) engages, the clutch pack causes the forward high output gear (2) to turn. The forward high output gear is splined to the forward high clutch pack (3). Gear (2) turns gear (15) on countershaft (5). Gear (15) and gear (13) are splined to the countershaft. Gear (15) turns the countershaft. Gear (13) turns gear (12) on the rear output shaft (6) .

Gear (12) is splined to the clutch pack for clutch 3 (11). When the clutch pack engages, the clutch pack turns the rear output shaft (6). Gear (14) is welded to the rear output shaft. Gear (12) turns gear (14). Gear (14) turns gear (10) on the front output shaft (9). Gear (10) is splined to the clutch pack for the front output shaft (8). When the clutch for the front output shaft engages, the clutch turns the front output shaft (10) .

Power Flow (First Speed Reverse)

Illustration 19	g00807981
Power flow in first speed reverse (1) Input shaft (2) Gear (3) Reverse clutch piston (4) Reverse clutch pack (5) Reverse output gear (6) Reverse shaft (7) Forward low output gear (8) Gear (9) Clutch pack for clutch 1 (10) Piston for clutch 1 (11) Output gear for clutch 1 (12) Countershaft (13) Gear (14) Rear output shaft (15) Piston for the front output shaft (16) Clutch pack for the front output shaft (17) Front output shaft (18) Gear (19) Gear (20) Gear

Illustration 20	g00807982
(21) Reverse solenoid

Illustration 21	g00807999
(22) Solenoid for clutch 1 (23) All wheel drive solenoid

When the transmission is in FIRST SPEED REVERSE, the solenoid for REVERSE (21) engages the REVERSE clutch (4) and the solenoid for clutch 1 (22) engages the clutch pack for clutch 1 (9). The all wheel drive solenoid (23) engages the clutch pack for the front output shaft (16) .

Torque from the engine is transferred through the torque converter to the shaft (1). Gear (20) is welded to the input shaft. Gear (20) turns gear (2). Gear (2) is welded to the reverse shaft (6) .

When the REVERSE clutch pack (4) engages, the clutch pack causes the reverse output gear (5) to turn. Gear (5) is splined to the reverse clutch pack. Gear (5) turns gear (8) on countershaft (12). Gear (8) is welded to the countershaft (12). Gear (8) turns the countershaft and gear (8) turns gear (7) on the input shaft (1) .

When the clutch pack for clutch 1 (9) engages, the clutch pack causes gear (11) to turn. Gear (11) is splined to the clutch pack. Gear (11) turns gear (13) on the rear output shaft (14). Gear (13) is splined to the rear output shaft. Gear (19) is welded to the rear output shaft. Gear (13) turns gear (19) .

Gear (19) turns gear (18) on the front output shaft (17). Gear (18) is splined to the clutch pack for the front output shaft (16). When the clutch pack for the front output shaft engages, the clutch pack turns the front output shaft (17) .

Power Flow (Second Speed Reverse)

Illustration 22	g00808006
Power flow in second speed reverse (1) Input shaft (2) Gear (3) Reverse clutch piston (4) Reverse clutch pack (5) Reverse output gear (6) Reverse shaft (7) Forward low output gear (8) Gear (9) Countershaft (10) Gear (11) Rear output shaft (12) Clutch pack for clutch 2 (13) Clutch piston for clutch 2 (14) Clutch piston for the front output shaft (15) Clutch pack for the front output shaft (16) Front output shaft (17) Gear (18) Gear (19) Gear (20) Gear

Illustration 23	g00808013
(21) Solenoid for clutch 2 (22) Reverse solenoid

Illustration 24	g00808015
(23) All wheel drive solenoid

When the transmission is in SECOND SPEED REVERSE, the solenoid for REVERSE (22) engages the REVERSE clutch pack (4) and the solenoid for clutch 2 (21) engages the clutch pack for clutch 2 (12). The all wheel drive solenoid (23) engages the clutch pack for the front output shaft (15) .

Torque from the engine is transferred through the torque converter to the input shaft (1). Gear (20) is welded to the input shaft. Gear (20) turns gear (2). Gear (2) is welded to the reverse shaft (6). When the REVERSE clutch (4) engages, the clutch causes the gear (5) to turn. Gear (5) is splined to the reverse clutch.

Gear (5) turns gear (8) on the countershaft (9). Gear (8) also turns gear (7) on the input shaft (1). Gear (8) is welded to the countershaft. Gear (19) is part of the countershaft. Gear (8) turns gear (19). Gear (19) turns gear (10) on the rear output shaft (11). Gear (10) is splined to the clutch pack for clutch 2 (12) .

Gear (18) is welded to the rear output shaft (11). When the clutch pack for clutch 2 (12) engages, the clutch turns gear (18) and the rear output shaft. Gear (18) turns gear (17) on the front output shaft (16). Gear (17) is splined to the clutch pack for the front output shaft (15). When the clutch pack for the front output shaft is engaged, the clutch pack turns the front output shaft.

Power Flow (Third Speed Reverse)

Illustration 25	g00808022
Power flow in third speed reverse (1) Input shaft (2) Gear (3) Reverse clutch piston (4) Reverse clutch pack (5) Reverse output gear (6) Reverse shaft (7) Forward low output gear (8) Gear (9) Countershaft (10) Gear (11) Rear output shaft (12) Clutch piston for the front output shaft (13) Clutch pack for the front output shaft (14) Front output shaft (15) Gear (16) Clutch piston for clutch 3 (17) Clutch pack for clutch 3 (18) Gear (19) Gear (20) Gear (21) Gear

Illustration 26	g00808028
(22) Solenoid for clutch 3 (23) Reverse solenoid

Illustration 27	g00808030
(24) All wheel drive solenoid

When the transmission is in THIRD SPEED REVERSE, the solenoid for REVERSE (23) engages the REVERSE clutch (4) and the solenoid for clutch 3 (22) engages the clutch pack for clutch 3 (17). The all wheel drive solenoid (24) engages the clutch pack for the front output shaft (13) .

Torque from the engine is transferred through the torque converter to the input shaft (1). Gear (21) is welded to the input shaft. Gear (21) turns gear (2). Gear (2) is welded to the reverse shaft (6). When the reverse clutch pack (4) engages, the clutch pack turns gear (5). Gear (5) is splined to the reverse clutch pack. Gear (5) turns gear (8) on the countershaft (9). Gear (8) turns gear (7) on the input shaft. Gear (8) is welded to the countershaft. Gear (8) turns the countershaft.

Gear (19) is splined to the countershaft (9). When the countershaft turns, gear (19) turns. Gear (19) turns gear (18) on the rear output shaft (11). Gear (18) is splined to the clutch pack for clutch 3 (17). Gear (20) is welded to the rear output shaft. When the clutch pack for clutch 3 engages, the clutch pack turns the rear output shaft and gear (20) .

Gear (20) turns gear (15) on the front output shaft (14). Gear (15) is splined to the clutch pack for the front output shaft (13). When the clutch pack for the front output shaft engages, the clutch turns the front output shaft.