F01.justanswer.com



Service Information SystemTuesday, April 12, 20165:53 PM?Disassembly and Assembly 416B, 426B, 428B, 436B & 438B BACKHOE LOADERS POWER TRAIN Media Number -SENR5803-03 Publication Date -01/08/2004 Date Updated -23/04/2013 ?SENR58030015TransmissionSMCS - 3060-015; 3060-016Disassemble TransmissionView ImageStart By: a. remove transmissionb. remove torque converterNOTE: For organization and clarity purposes, the transmission will be disassembled into major components and then those components disassembled.Disassmble the transmission as follows: 1. Install the transmission onto tooling (A).View Image2. Remove drain plug (1) and drain the transmission oil into a suitable container.View Image3. Remove six bolts (2). Remove control valve assembly (3) and gasket.View Image4. Using tooling (A), rotate the entire transmission.View Image?5. Remove yoke bolt and yoke (4).View Image6. Remove three bolts (5). Remove control assembly (6) with anti-rotation pin (7). Remove lower seating and O-ring.NOTE: Use care when removing the control assembly to insure that anti-rotation pin (7) does not slip out during removal. View Image7. Remove eleven bolts and remove rear cover (9) and gasket (10).View Image8. Remove countershaft and output shaft shim packs (11). Use a piece of wire of tape to keep each of the shim packs separate from the other. Label each of the shim packs to insure that it is reassembled properly.View Image9. Remove lockscrew (13) then remove shift lugs (12).View Image10. Remove two bolts and remove interlock plate (14). Remove two interlock balls (15) using a suitable magnet.View Image11. Engage two gears by taping down shaft rods (16).View Image12. Remove reverse idler nut (18), washer (17) and gear (19).View Image13. Install tooling (B) to rear case (20). Using a soft metal drift, tap the idler shaft to free the spline, then remove fifteen bolts and remove rear case (20) and gasket (21). Also remove bearing (not shown). Weight of rear case is 34 kg (75 lb).View Image14. Remove idler pinion, bearing and spacer (22). Also remove any remaining bearing shells.View Image15. Flatten the lock tabs, remove one bolt (23) and remove suction pipe (24).View Image16. Lift and tilt countershaft (26) and remove input shaft assembly (25). After this is completed return countershaft (26) to its original position.View Image17. Remove two detent plugs (29), springs (28) and balls (27).View Image18. Lift and tilt countershaft (26) and then remove output shaft (30) and shift fork assembly (31).View Image19. Remove countershaft (26) from the transmission case.View Image20. Remove shifting forks and rods (31).NOTE: If the forks are removed from the rods, clearly mark each so that it can be put back in the same position during reassembly. View Image21. Remove oil feed pipe (32).View Image22. Remove eight bolts (33) and remove front wheel drive unit (34) and gasket. Weight of front wheel drive unit (34) is 34 kg (75 lb).View Image23. Remove two bolts (35) and oil filter housing (36).View Image24. Remove two bolts (37) and oil strainer retaining plate (38), O-ring (39) and oil strainer (40).View Image25. Install tooling (B) as shown and remove eight bolts (41) and remove converter housing (42).View Image26. Remove four bolts and washers (43) and remove oil pump and sealing ring (not shown).View Image27. Remove three bearing races (45).Disassemble the transmission oil pump as follows: NOTE: The oil pump can be disassembled if any form of contamination was present in the transmission. Disassembly of the oil pump however, is not generally recommended since individual components are nonservicable. If a major transmission overhaul is required, the oil pump should be cleaned or if necessary replaced. View Image1. Remove drive gear (1) from torque converter coupling (2).View Image2. Remove gear (3).View Image3. Remove oil seal (4).Disassemble the transmission countershaft as follows: View Image1. Using tooling (C) and a press, remove gear (2) and bearing (1).View Image2. Turn the countershaft over and install tooling (C) and a press. Remove bearing (3).Disassemble the transmission input shaft as follows: View Image1. Remove seal rings (1).View Image2. Install tooling (D) and remove rear bearing (2).View Image3. Remove washer (3), thrust disc (4) and anti-rotation pin (5).View Image4. Remove reverse primary gear (6).View Image5. Remove bearings (7), washer (8) and anti-rotation pin (9).View Image6. Remove spring retainer (10) and retainer (11) and clutch plates (12).View Image7. Install tooling (E). Remove snap ring (13). Using tooling (E), compress spring pack (14).View Image8. Remove spring pack (14).View Image9. Turn the shaft assembly over and remove sealing ring (16).View Image10. Install tooling (G) and remove bearing (17).View Image11. Remove washer (18), disc (19) and anti-rotation pin (20).View Image12. Remove forward primary gear (21).View Image13. Remove bearing (22), washer (23) and anti-rotation pin (24).View Image14. Remove retaining ring (25), retainer (26) and clutch plates (27).View Image15. Using tooling (H), remove snap ring (28).NOTE: Do not reuse snap ring (28). View Image16. Remove spring assembly (29).?Always wear protective eye wear when using compressed air. Insure that the air nozzle has been reduced in pressure to comply with OSHA regulations. View Image17. Using a suitable source of compressed air and the proper approved nozzle, force air into the hydraulic ports. Remove the forward piston and then the reverse piston.View Image18. Remove center seal (30) and outer seal (31) from piston (32).Disassemble the transmission output shaft as follows: View Image1. Position the shaft vertically. Using tooling (D), remove bearing (1) and the spacer below it.View Image2. Remove drive gear (2) and first gear (3).View Image3. Remove two bearings (4) and spacer (5).View Image4. Remove first and second gear synchronizer assembly (6).View Image5. Using tooling (F) under second gear (9), remove first gear bearing sleeve (7), synchronizer sleeve (8) and second gear (9).View Image6. Turn the shaft over and using tooling (D), remove bearing (10).View Image7. Remove fourth gear (11). Remove third and forth gear synchronizer.View Image8. Remove snap ring (13). Remove third and fourth gear synchronizer sleeve (14).View Image9. Remove third gear (15).Disassemble the transmission control valve as follows: NOTE: This control valve is used on the following models and serial numbers: 416B 8SG1-UP, 8ZK1-UP, 426B 5YJ1-UP, 6KL1-UP 428B 7EJ1-UP 436B 6MJ1-UP, 7FL1-UP 438B 3KK1-UP. View Image1. Remove solenoid (1), seal (2), spool (3) and spring (4).View Image2. Remove plug and seal (7), three springs (6) and spool (5).View Image3. Remove plug and seal (10), spring (9) and ball (8).View Image4. Remove switch and seal (11) and three balls (12).View Image5. Remove plug and seal (14) and spool (13).View ImageView ImageNOTE: Examine selector assembly (16) carefully prior to disassembly. Disassemble only if necessary. Assembly is difficult. 6. Remove snap ring (15).7. Remove selector assembly (16) and seal (17).8. Remove detent ball (19) and spring (18).Disassemble the transmission hydraulic four wheel drive as follows: NOTE: This control valve is used on the following models and serial numbers: 416B 8SG1-UP, 8ZK1-UP, 426B 5YJ1-UP, 6KL1-UP 428B 7EJ1-UP 436B 6MJ1-UP, 7FL1-UP 438B 3KK1-UP. View Image1. Flatten the tab washer and remove bolt (1). Remove washer (2) and output coupling (3).View Image2. Remove four bolts (4), cover (5) and gasket (not shown).View Image3. Remove spacer (6) and shims (7).View Image4. Remove four wheel drive assembly over and flatten tab washer and remove nut (8) and washers.NOTE: It will be necessary to secure the shaft to remove nut (8) from shaft. View Image5. Remove solenoid (9), spool (10), and spring (11).View Image6. Remove four bolts (12). Remove control housing (13) and O-rings (14).View Image7. Remove sleeve (15) and O-ring seal (16).View Image8. Install four wheel drive assembly in a press and remove output shaft and bearing (17).NOTE: If lower bearing does not stay on the shaft when the shaft is removed from the case, remove lower bearing from the case. View Image9. Remove gear (22), (23) and (24), bearings (29), washers (26), (27), (28), clutch plates (25), cover (20) and spring pack (21).View Image10. Remove seal rings (30) from sleeve (15).View Image11. Remove all remaining O-rings (31) and seal ring (32) from piston (33).View Image12. Remove O-ring (34) from cylinder (20).Assemble TransmissionView ImageAssemble the transmission oil pump as follows: NOTE: For organization and clarity purposes, the transmission will be assembled into major components and then those components assembled into the finished transmission. View Image1. Install oil seal (4).View Image2. Install gear (3).View Image3. Install drive gear (1) into the torque converter housing.Assemble the countershaft as follows: View Image1. Heat bearing (3) to a temperature of 275°F and install bearing on countershaft (2).View Image2. Turn countershaft (2) over. Heat bearing (1) to a temperature of 275°F and install it on countershaft (2).Assemble the input shaft as follows: View Image1. Replace O-rings (30). Replace seal (31) on piston (32). Prior to installing seal (31), soak seal (31) in warm water. This will make the seal flexible and prevent cracking or distortation.View Image2. Using tooling (J), to compress seal (31). Leave seal (31) in tooling (J) for approximately 30 minutes. This will compress the seal enough so that it will easily install into the drum clutch without damage. Remove piston (32) with the seal and install into the forward side of the clutch drum. Turn the clutch drum over and repeat the procedure with the reverse piston.View Image3. Install spring pack (29). Using tooling (H), secure the spring pack with a new snap ring (28).View Image4. Install anti-rotation pin (24) and thrust washer with the oil grooves facing up.View Image5. Install forward gear bearings (22) and gear (21).View Image6. Install anti-rotation pin (20). Install plastic washer (19) with the boss located inside the plastic washer. Install the metal washer (18).View Image7. Install clutch pack (27) starting with a plate and alternating between plate and disc.View Image8. Install retainer (26) as shown with the recess upward. Secure with snap ring (25).View Image9. Heat bearing (17) to a temperature of approximately 275°F and install on shaft. It may be necessary to use to use the appropriate sleeve and press bearing (17) into place. Install seal ring (16).View Image10. Using tooling (E), install spring pack (14) and secure a new snap ring (13).View Image11. Install anti-rotation pin (9) and thrust washer (8) with oil grooves facing upward.View Image12. Install reverse gear bearing (7) and gear (6).View Image13. Install anti-rotation pin (5), plastic washer (4) and metal washer (3).View Image14. Install clutch pack (12) starting with a plate and alternating between plate and disc.View Image15. Install retainer (11) as shown with the recess upward and secure with snap ring (10).View Image16. Heat bearing (2) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (2) into place.View Image17. Install seal rings (1).Assemble the transmission output shaft as follows: View Image1. Install third gear (15) as shown with teeth of smaller portion of gear facing upward.View Image2. Install synchronizer (14) and snap ring (13).View Image3. Install third and fourth gear synchronizer (12) with the extended cup facing upward.4. Install fourth gear (11) with teeth of smaller portion of the gear facing upward.View Image5. Heat bearing (10) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (10) into place.View Image6. Turn the shaft over and install second gear (9) as shown, with teeth of smaller portion of gear facing upward. Install first and second gear synchronizer (8).View Image7. Heat bearing (7) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (7) into place.View Image8. Install the first and second gear synchronizer assembly (6). Install first gear bearings (4) and spacer (5).View Image9. Install first gear (3). Install first gear (3) as shown with teeth of smaller portion of gear facing downward.View Image10. Replace drive gear (2) with oil grooves facing down.View Image11. Heat bearing (11) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (1) into place.Assemble the transmission as follows: View Image1. Replace the seal ring (3) between oil pump (1) and transmission housing (4). Install four bolts and washers (2) securing oil pump and tighten to a torque of 17 to 31 N·m (13 to 23 lb ft).2. Install the torque converter housing and secure with bolts. Tighten to a torque of 83 to 111 N·m (60 to 80 lb ft).View Image3. Turn the transmission housing over and replace three front bearing races (5), (6) and (7). Insure that each race is totally seated.View Image4. Install oil feed pipe (8). Secure pipe (8) using two special bolts (9). Use 9S3263 Threadlocker on the threads of bolts (9) and tighten to a torque of 34 to 41 kg (25 to 30 lb).View Image5. Install idler pinion, spacer, bearings and gears (11) and secure to a torque of 125 to 136 kg (90 to 100 lb).6. Using tooling (K) measure idler shaft end play and select a suitable shim pack to attain an end play of .076 to .152 mm (.003 to .006 in). This will give the proper amount of preload to the idler gear. After the measurement has been determined, perform step 5 and 6 again.View Image7. Install assembled input shaft assembly (12) into front case.View Image8. Install the input shaft bearing race into the rear case. Install a gasket and install the rear case (13) and secure with case bolts.View Image9. Using tooling (K) measure input shaft end play and select a suitable shim pack to attain an end play of .025 to .076 mm (.001 to .003 in). This will give the proper amount of preload to the idler gear. After the measurement has been determined, perform step 9 again.10. Remove the rear case and insert the proper shim pack below the bearing cones, then remove the input shaft.View Image11. Install assembled output shaft assembly (15). Install shifting forks (14) as shown. It may be necessary to slightly lift and fit the forks into the output shaft.View Image12. Install countershaft assembly (16). To install countershaft (16) it will be necessary to raise the output shaft and forks slightly.NOTE: After the installation of each of the gear assemblies into the transmission housing, each assembly should be turned to insure that it does not bind and that all gears mesh. View Image13. Install input shaft (17).View Image14. Install oil suction pipe (18) and secure with bolt (19). Tighten bolt (19) to a torque of 18 to 31 N·m (13 to 23 lb ft). Lock bolt (19) by bending the lock tabs on the corner of bracket holding tube (18).View Image15. Engage second gear as shown, then position idler pinion, bearing and spacer (20) on the input shaft and shift fork.View Image16. Install a new gasket between the two portions of the transmission case. Using tooling (B), install rear cover (22).View Image17. Install reverse idler shim (23), spacers (24), bearing (25), gear (26), washer (27) and nut (28). Tighten nut to a torque of 122 to 136 N·m (90 to 100 lb ft).View Image18. Install interlock detent balls (29). Return the transmission to the neutral position, then replace interlock detent plate (30). Tighten two bolts (31) in the interlock detent plate to a torque of 8 to 16 N·m (6 to 12 lb ft).View Image19. Instal first and second shift lugs (33) and third and fourth shift lugs (34). Tighten Allen locking nut (32) on each of the lugs to a torque of 18 to 24 N·m (13 to 18 lb ft).View Image20. Using a suitable depth gauge, measure the depth of the bearing race from the case. Add .12 mm (.005 in) to this figure. Select a suitable shim so that the shaft end play is .025 to .076 mm (.001 to .003 in).View Image21. Repeat step 20 for output shaft (15).View Image22. Install required shims (35) that are needed for steps 20 and 21.View Image23. Install seal (36) in cover (37).View Image24. Install a new gasket and install cover (37) onto the transmission case. Install eleven bolts (38) and tighten to a torque of 44 to 64 N·m (33 to 47 lb ft).View Image25. Install O-ring (39) onto the lower seat (40) of stub lever (41). Install a new gasket between housing and upper seat (42). Install upper seat (42) and three bolts (43) to secure upper seat. Tighten three bolts (43) to a torque of 18 to 31 N·m (13 to 23 lb ft).View Image26. Install detent ball (44), spring (45) and plug (46). Install new O-ring on plug (46). Tighten plug (46) to a torque of 40 to 54 N·m (30 to 40 lb ft).View Image27. Install suction strainer O-ring (47), washer (49) and retaining plate (48). Secure with bolts (47) and tighten to a torque of 18 to 31 N·m (13 to 23 lb ft).View Image28. Install a new gasket and 7M7260 Gasket Maker and install oil filter housing (51). Secure with two bolts (52) and tighten to a torque of 45 to 64 N·m (33 to 47 lb ft).View Image29. Install a new gasket and 7M7260 Gasket Maker and install four wheel drive unit (53) and secure with four bolts (54). Tighten bolts (54) to a torque of 45 to 64 N·m (33 to 47 lb ft).View Image30. Install a new gasket and 7M7260 Gasket Maker and install control valve unit (55) and secure with five bolts (56). Tighten bolts to a torque of 31 to 41 N·m (23 to 30 lb ft).View Image31. Install oil drain plug (57) and tighten to a torque of 34 to 54 N·m (25 to 40 lb ft).View Image32. Install output coupling (58). Use care not to destroy or damage the new oil seal.Assemble the transmission control valve as follows: NOTE: This control valve is used on the following models and serial numbers: 416B 8SG1-UP, 8ZK1-UP, 426B 5YJ1-UP, 6KL1-UP 428B 7EJ1-UP 436B 6MJ1-UP, 7FL1-UP 438B 3KK1-UP.NOTE: Prior to assembly, replace all old oil seals and gaskets with new. View Image1. Install spring (18) and ball (19) into hole in selector assembly.2. Install new seal (17) on selector assembly (16) and install selector assembly while holding detent ball back.3. After selector assembly is in position and working properly, install snap ring (15).View Image4. Install spool (13) as shown and seal and plug (14). Tighten plug (14) to a torque of 27 N·m (20 lb ft).View Image5. Install three balls (12), seal and switch (11).View Image6. Install ball (8), spring (9) and seal and plug (10).View Image7. Install first spring (6), spool (5), second and third spring (6) and seal and plug (7). The second spring (6) sits inside the third spring (6).View Image8. Install spring (4), spool (3), a new seal (2) and solenoid (1). Tighten solenoid to a torque of 34 to 54 N·m (25 to 40 lb ft).Assemble the transmission four wheel drive transfer gear box as follows: NOTE: Prior to assembly, replace all oil seals, O-rings and gaskets. It is also important to soak the clutch pack plates in clean oil for three hours. View Image1. Install O-ring seal (34) in cylinder (20).View Image2. Soak piston seal ring (32) in warm water and install the seal as shown on piston (33). Install O-ring (31).View Image3. Install piston (33) with seal (32) into tooling (J), and leave for 30 minutes. This will compress the seal for easy assembly.View Image4. Install piston (33) into cylinder (20).View Image5. Install clutch plates (25) into splined gear hub (22) starting with an internally splined friction disc and alternating with externally splined discs.View Image6. Install thrust washer (26). Install clutch hub (24) into lower hub (22).View Image7. Position spring pack (21) over the spring locations, then reposition cylinder (20) and piston and spring unit as shown.View Image8. Position case (18) as shown.View Image9. Install the gear assembly (19) into the case (18) as shown.View Image10. Heat and install bearing (17) onto shaft.View Image11. Install anti-rotation pin (35) into output shaft. Install the output shaft through case assembly (18).NOTE: Make sure that the anti-rotation pin lines up with the slot in the cylinder. View Image12. Install bearing (17) outer race and O-ring (16).View Image13. Install seals (30) onto sleeve (15) as shown.View Image14. Install sleeve (15) with the smaller chamfer upward.View Image15. Install O-rings (14) and insure that they are correctly seated. Install control housing (13) and secure with four bolts (12). Tighten bolts (12) to a torque of 45 to 64 N·m (33 to 47 lb ft).View Image16. Turn the unit over and install the sleeve and bearings (29).View Image17. Install spacer (6) and shim (7).View Image18. Heat bearing and install onto shaft. Install bearing race.NOTE: Check that the lower clutch plates do not become dislodged. View Image19. Install spacer and washer. Install nut (8) and tighten to a torque of 112 to 144 N·m (90 to 120 lb ft).View Image20. Install spacer, gasket and end cover (5) and secure with four bolts (4). Tighten to a torque of 45 to 64 N·m (33 to 47 lb ft).View Image21. Turn four wheel drive assembly over and install a dial indicator, measure the end play of the drive assembly. Install the appropriate shims to allow end play of .02 to .07 mm (.001 to .003 in). Shimming procedure is covered in the next step.View Image22. Turn drive assembly over and remove four bolts (4), cover (5) and spacer (6). Install the necessary shims (7). Install a new gasket and install cover, spacer and four bolts. Tighten bolts to a torque of 45 to 64 N·m (33 to 47 lb ft).View Image23. Install output yoke (3), O-ring and washers (2). Secure with bolt and tighten to a torque of 68 to 88 N·m (50 to 65 lb ft). Bend lock tabs over bolt head to lock in position.View Image24. Install spring (11) (not shown), and spool (10). Make sure that the large chamfer is facing upward. Install solenoid (9) and tighten to a torque of N·m (25 to 40 lb ft).End By: a. install torque converterb. install transmission?Copyright 1993 - 2016 Caterpillar Inc.All Rights Reserved.Private Network For SIS Licensees.? Tue Apr 12 2016 17:39:22 GMT-0500 (Central Daylight Time) ?Inserted from <; ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download