Caterpillar cat 415 f2 il backhoe loader (prefix pf4) service repair manual (pf400001 and up)

Service Repair Manual
Models
415F2 IL Backhoe Loader

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Product: INDUSTRIAL LOADER
Model: 415F2 IL INDUSTRIAL LOADER PF4
Configuration: 415F2 IL Backhoe Loader PF400001-UP (MACHINE) POWERED BY C3.4 Engine
Disassembly and Assembly
415F2 Industrial Loader Power Train
Media Number -M0067026-00 Publication Date -01/05/2015 Date Updated -12/05/2016
i06559073
Transmission (Direct Drive) - Disassemble
SMCS - 3030-015-DD; 3066-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 395-1590 Lifting Eye Assembly 2
B 422-5471 Lifting Eye Assembly 1
C 4C-3652 Spring Compressor 1
D 1P-1859 Retaining Ring Pliers 1
E 8H-0663 Bearing Puller Gp 1
F 8B-7551 Bearing Puller Gp 1
G 1U-6400 Three Jaw Puller 1
H 137-8102 Spring Compressor 1
Start By:
a. Remove the transmission.
1/33415F2 IL Backhoe Loader PF400001-UP (MACHINE) POWERED BY C3.4 Engine(...
2019/12/3https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

Illustration 1 g03827943
1. Use two people to remove torque converter (1). The weight of torque converter (1) is
approximately 23 kg (51 lb). Remove torque converter (1) from transmission (2).
2. Remove bolt (4), the washer, and yoke (3) from transmission (2).
3. Remove shaft (5) from transmission (2).
4. Remove bolts (7) and gear shift (6) from transmission (2).
5. Remove bolts (10) and support assemblies (8) from transmission (2).
6. Remove bolt (11), the washer, and yoke (9) from transmission (2).

7. Remove bolts (13) and solenoid valve (12) from transmission (2).
Personal injury can result from being struck by parts propelled by a
released spring force.

Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
8. Remove head (14) from solenoid valve (12). Remove O-ring seal (15) from head (14).
9. Remove spring (16), carrier (17), spring (18), and piston (19) from solenoid valve (12).

10. Remove plug (20) from solenoid valve (12). Remove O-ring seal (21) from plug (20).
11. Remove spring (22) and poppet (23) from solenoid valve (12).
12. Remove self-locking nut (24), O-ring seal (26) coil assembly (25), and O-ring seal (27)
from solenoid valve (12).

13. Remove tube assembly (28) from solenoid valve (12). Remove O-ring seal (29) from tube
assembly (28).
14. Remove spring (30), push rod (31), washer (32), and spool (33) from solenoid valve (12).
15. Remove O-ring seals (34) from solenoid valve (12).
16. Repeat Step 8 through Step 14 for the opposite side of solenoid valve (12).

17. Attach Tooling (A) and a suitable lifting device to transmission (2). The weight of
transmission (2) is approximately 255 kg (562 lb). Place transmission (2) on a suitable work
bench. Secure transmission (2) to the suitable work bench.
18. Remove bolts (35) that secure the case.
19. Attach Tooling (A) and Tooling (B) to case (36). The weight of case (36) is approximately
45 kg (100 lb). Remove case (36) from the transmission.
Direct Drive, Front Output Shaft

1. Remove front output shaft (37).
2. Use suitable press to remove bearing cone (38).
3. Remove bearing cone (38), thrust washer (39), needle bearing (40), and gear (41) from the
shaft.

4. Remove roller bearing (42), spacer (43), roller bearing (44), needle bearing (45), and thrust
washer (46) from the shaft.
5. Remove retaining ring (47).
6. Remove plate (48).

7. Remove friction disks (49) and friction clutches (50).
8. Use a suitable press and Tooling (C) to compress spring assembly (52). Use Tooling (D) to
remove retaining ring (51).
10/33415F2 IL Backhoe Loader PF400001-UP (MACHINE) POWERED BY C3.4 Engin...

9. Remove spring assembly (52) and retainer (53).
10. Release piston (54) by applying 207 kPa (30 psi) of air pressure into the lube passage as
indicated.
11. Remove seal ring (55).

12. Use Tooling (E) and a suitable press to remove bearing cone (56). Remove bearing cone
(56).
Direct Drive, Rear Output Shaft
1. Remove plug (57), spring (59), and ball (58).

2. Remove screws (60) from the shift forks. Remove rod (61) and ball (62).

Note: Reinstalling plug (57) keeps the spring and the ball from being propelled from the
transmission case.
3. Reinstall plug (57) into the transmission case.
4. Remove rod (63) and shift forks (64).

5. Remove plug (57), ball (67), and spring (66).
6. Remove rear output shaft (65).
7. Remove screw (69) and washer (68).
8. Use Tooling (F) and a suitable press to remove bearing cone (70) and gear (71).

9. Remove needle bearings (72) and (73).
10. Use Tooling (D) to remove lock ring (74).
11. Remove synchronizer assembly (75).
12. Remove sleeve (76).

13. Remove gear (77).
14. Remove needle bearings (78) and (79).

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15. Use a suitable press to remove bearing cone (80) from the shaft. Remove bearing cone (80),
gear (89), gear (90).
16. Remove shims (81), synchronizer assembly (82), and shims (83).
17. Remove bearing (84), bearing spacer (85), and sleeve (86).
18. Remove sleeve (87), gear (88), bearing spacer (91), and bearing (92).
Direct Drive Shaft
1. Remove direct drive shaft (93).

2. Use Tooling (F) and a suitable press to remove bearing cone (94). Remove bearing cone
(94).
3. Use Tooling (E) and a suitable press to remove bearing cone (95). Remove bearing cone
(95).
Direct Drive, Reverse Shaft

1. Remove reverse shaft (96).
2. Remove ring seals (97).
3. Use Tooling (G) to remove bearing cone (98). Remove bearing cone (98), thrust washer
(100), bearing (101), and gear (99).

4. Remove needle bearing (102) and thrust washer (103).
5. Remove retaining ring (104) and end plate (105).
6. Remove clutch pack (106).

Caterpillar cat 415 f2 il backhoe loader (prefix pf4) service repair manual (pf400001 and up)

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