service repair manual

1. Service Repair Manual
Models
416D Backhoe Loader

2. Shutdown SIS
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Product: BACKHOE LOADER
Model: 416D BACKHOE LOADER BFP
Configuration: 416D Backhoe Loader BFP05178-17198 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
416D, 420D, 424D, 428D, 430D, 432D, 438D and 442D Backhoe Loaders Power
Train
Media Number -RENR3578-12 Publication Date -01/04/2010 Date Updated -13/04/2010
i02557471
Transmission (Power Shift) - Assemble
SMCS - 3030-016-PM; 3066-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 152-7055 Spring Compressor 1
B
152-7085 (1)
Transmission Shaft Handler 1
189-0409 Shackle As 1
C 6V-2157 Link Bracket 1
D 8T-5096 Indicator 1
E 1U-5702 Repair Stand 1
( 1 )
CE Compliant
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.
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3. Note: O-rings, gaskets, and seals should always be replaced. A used O-ring may not have the
same sealing properties as a new O-ring. Use 1U-6396 O-Ring Assembly Compound during the
assembly procedure.
Illustration 1 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.
Reverse Shaft
Illustration 2 g00730943
1. Install seal (195) and the O-ring on piston (195) .
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4. Illustration 3 g00731347
2. Install piston assembly (194) .
Illustration 4 g00731350
3. Install spring assembly (193) .
Illustration 5 g00731351
4. Use tooling (A) in order to compress the spring assembly. Install retaining ring (192) .
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5. Illustration 6 g00731352
5. Install eight friction discs (190) and eight plates (191) .
Illustration 7 g00731353
6. Install end plate (189) .
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6. Illustration 8 g00731355
7. Install retaining ring (188) .
Illustration 9 g00731356
8. Install washer (187) and needle thrust bearing (186) .
Illustration 10 g00731357
9. Install caged roller bearing (185) , the spacer, and caged roller bearing (183) .
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7. Illustration 11 g00731358
10. Install gear (184) .
Illustration 12 g00731359
11. Install needle thrust bearing (182) and washer (181) .
Illustration 13 g00731360
12. Heat bearing (180) to 135 °C (275 °F). Install bearing (180) .
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8. Illustration 14 g00731361
13. Install two rings (179) .
Illustration 15 g00731362
14. Heat bearing (197) to 135 °C (275 °F). Install bearing (197) .
Input Shaft
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9. Illustration 16 g00730839
1. Install seal (159) and the O-ring on piston (160) .
Illustration 17 g00731365
2. Install piston assembly (158) .
Illustration 18 g00731366
3. Install spring assembly (157) .
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10. Illustration 19 g00731367
4. Use tooling (A) in order to compress the spring assembly. Install retaining ring (156) .
Illustration 20 g00731368
5. Install eight friction discs (154) and eight plates (155) .
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11. Illustration 21 g00731369
6. Install end plate (153) .
Illustration 22 g00731856
7. Install retaining ring (152) .
Illustration 23 g00731857
8. Install washer (151) and needle thrust bearing (150) .
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12. Illustration 24 g00731858
9. Install caged roller bearing (149) , spacer (148) , and caged roller bearing (147) .
Illustration 25 g00731859
10. Install gear (146) .
Illustration 26 g00731861
11. Install needle thrust bearing (145) and washer (144) .
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13. Illustration 27 g00731865
12. Install retaining ring (143) .
Illustration 28 g00731866
13. Heat bearing (142) to 135 °C (275 °F). Install bearing (142) .
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14. Illustration 29 g00731867
14. Install four rings (141) .
Illustration 30 g00731868
15. Install seal (176) and the O-ring on piston (177) .
Illustration 31 g00731870
16. Install piston assembly (178) .
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16. Illustration 32 g00731871
17. Install spring assembly (175) .
Illustration 33 g00731897
18. Use tooling (A) in order to compress the spring assembly. Install retaining ring (174) .
Illustration 34 g00731898
19. Install eight friction discs (172) and eight plates (173) .
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17. Illustration 35 g00731899
20. Install end plate (171) .
Illustration 36 g00731900
21. Install retaining ring (170) .
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18. Illustration 37 g00731902
22. Install washer (169) , needle thrust bearing (168) , caged roller bearing (167) , and caged
roller bearing (166) .
Illustration 38 g00731904
23. Install gear (165) .
Illustration 39 g00731906
24. Install needle thrust bearing (164) and washer (163) .
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19. Illustration 40 g00731908
25. Heat bearing (162) to 135 °C (275 °F). Install bearing (162) .
Illustration 41 g00731910
26. Install ring (161) .
Shaft
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