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

Transmission (Direct Drive) - Disassemble

Usage:

416D B2D

Disassembly Procedure

Show/hide table

Table 1
Required Tools
Tool	Part Number	Part Description	Qty
A	1U-5750	Engine Stand	1
B	6V-2157	Link Bracket	1
C	9S-9152	Puller Assembly	1
C	5F-7465	Puller	1
C		3/8inch x 6inch Bolt	2
D	4C-3652	Spring Compressor	1
E	1U-6405	Puller	1
F	4C-3802	Puller	1
G	8H-0663	Puller	1
G	5F-7465	Puller	1
H	8B-7551	Puller	1
H	6V-3010	Puller	1
I	137-8102	Spring Compressor	1
J	4C-3089	Puller	1
K	1P-1859	Snap Ring Pliers	1

Start By:

Remove the transmission. Refer to Disassembly and Assembly, "Transmission (Direct Drive) - Remove".

Show/hide table

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 Tools and Shop Products Guide" 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.

Show/hide table




Illustration 1	g00728888

Install transmission (1) on tooling (A) .

Show/hide table




Illustration 2	g00728895

Remove Implement pump drive shaft (2) from transmission (1) .

Show/hide table




Illustration 3	g00728902

Remove plug (3). Drain the transmission oil into a suitable container. The capacity of the transmission is 11.3 L (3 US gal).

Show/hide table




Illustration 4	g00728906

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

Show/hide table




Illustration 5	g00728913

Attach tooling (B) to case (7). Attach a suitable lifting device to tooling (B). Remove fourteen bolts (8). Remove case (7) from the transmission. The weight of case (7) is 42 kg (94 lb).

(Direct Drive) Output Shaft (Front)

Show/hide table




Illustration 6	g00728940

Remove front output shaft (9) .

Show/hide table




Illustration 7	g00728943

Use tooling (C) in order to remove bearing cone (10) .

Show/hide table




Illustration 8	g00728944

Use tooling (E) in order to remove bearing cone (11) and gear (12) .

Show/hide table




Illustration 9	g00728945

Remove two roller bearings (13), spacer (14), needle bearing (15), and thrust washer (16) .

Show/hide table




Illustration 10	g00728948

Remove retainer (17) and clutch pack (18) .

Show/hide table




Illustration 11	g00728950

Use a suitable press and tooling (D) in order to compress spring (19). Use tooling (K) in order to remove snap ring (20) .

Show/hide table




Illustration 12	g00728952

Remove snap ring (20), retainer (21), and spring (19) .

Show/hide table




Illustration 13	g00728953

Release piston (22) by blowing shop air into the lube passage, as shown.

Show/hide table




Illustration 14	g00729060

Use a seal pick in order to remove the seals from piston (22) .

(Direct Drive) Output Shaft (Rear)

Show/hide table




Illustration 15	g00729062

Remove screws (24) from each of the gearshift rods (23) .

Show/hide table




Illustration 16	g00729064

Remove plug (25) .

Show/hide table




Illustration 17	g00729196

Remove plug (25), O-ring (26), two springs (27), and three balls (28). Remove two gearshift rods (23) from shift forks (29) .

Show/hide table




Illustration 18	g00729197

Use tooling (E) in order to remove bearing (30), gear (31), and gear (32) .

Show/hide table




Illustration 19	g00729198

Remove bearings (33), spacer (34), and synchronizer (35) .

Show/hide table




Illustration 20	g00729199

Use tooling (F) in order to remove bearing (36) and gear (37). Remove synchronizer (38) .

Show/hide table




Illustration 21	g00729200

Use tooling (K) in order to remove snap ring (39). Remove gear (40) and housing (41) .

Show/hide table




Illustration 22	g00729201

Use tooling (E) in order to remove gear (42) .

(Direct Drive) Shaft

Remove the shaft by hand for disassembly.

Show/hide table




Illustration 23	g00729202

Use tooling (G) in order to remove bearings (43) and (44) .

(Direct Drive) Reverse Shaft

Remove the reverse shaft by hand for disassembly.

Show/hide table




Illustration 24	g00729204

Use tooling (G) in order to remove bearings (45) and (46) .

(Direct Drive) Input Shaft

Remove the input shaft by hand for disassembly.

Show/hide table




Illustration 25	g00729207

Use tooling (H) in order to remove bearing (47) .

Show/hide table




Illustration 26	g00729208

Use tooling (K) in order to remove snap ring (48). Remove spacer (49), needle bearing (50), and gear (51) .

Show/hide table




Illustration 27	g00729210

Remove retainer (52) and clutch pack (53) .

Show/hide table




Illustration 28	g00729213

Use tooling (I) and a suitable press in order to compress spring (55). Use tooling (K) in order to remove snap ring (54). Remove the retainer and spring (55) .