416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D 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 thoroughly cleaned 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.

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

Transmission case

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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	g00729752

3. Install piston (56). Install the retainer and spring (55). Use tooling (A) and a suitable press in order to compress spring (55). Use tooling (B) in order to install snap 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). Use tooling (B) in order to install snap ring (48) .

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Illustration 7	g00729771

7. Heat bearing cone (57) to 135 °C (275 °F). Install bearing cone (57) .

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

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). Use tooling (B) in order to install snap 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	g00729196

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Illustration 16	g00729064

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 (26). Install plug (25) .

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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	g00730110

2. Install piston (22), spring (19), and retainer (21) .

3. Use tooling (C) and a suitable press in order to compress spring (19). Use tooling (B) in order to install snap 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

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Illustration 26	g00730114

Note: Clean the mating surfaces of case (7). Apply a continuous bead of 1U-8846 Sealant to the mating surface of the case.

1. Attach tooling (D) to case (7). Attach a suitable lifting device to tooling (D). Use fourteen bolts (8) in order to install case (7). The weight of case (7) is 42 kg (94 lb).

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Illustration 27	g00730079

2. Install a bolt in the output shaft. The output shaft must be fully seated. Install tooling (E), as shown. Zero tooling (E). Pry up on the bolt and record the reading on tooling (E). The reading must be 0.03 mm (0.0012 inch) to 0.08 mm (0.0031 inch). Add or remove shims in Step 1 in the Case Assembly Procedure in order 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 in order to check the input shaft. Use a screwdriver to pry up on the input shaft. Install a new 1H-9721 Expansion Plug .

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Illustration 29	g00728906

4. Install yoke (4), washer (5), and bolt (6) .

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Illustration 30	g00728902

5. Install plug (3) .

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Illustration 31	g00728895

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

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Illustration 32	g00730116

7. Remove transmission (1) from tooling (F) .

End By: Install the transmission. Refer to Disassembly and Assembly, "Transmission (Direct Drive) - Install".