Caterpillar cat 438 c backhoe loader (prefix 1tr) service repair manual (1tr00001 01283)

Service Repair Manual
Model
438C BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438C BACKHOE LOADER 1TR
Configuration: 438C Backhoe Loader Side Shift, Parallel Lift 1TR00001-01283 (MACHINE) POWERED BY 3054 Engine
Disassembly and Assembly
416C, 426C, 428C, 436C, & 438C BACKHOE LOADERS POWER TRAIN
Media Number -SENR1206-02 Publication Date -01/11/2003 Date Updated -26/02/2018
SENR12060009
Final Drive And Axle Housing (Rear) (All Wheel Steer)
SMCS - 4050-015; 4050-016
Disassemble Final Drive And Axle Housing (Rear) (All Wheel
Steer)
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with
suitable containers before opening any compartment or disassembling any component containing
fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to
collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations
and mandates.
NOTE: For photographic purposes, the all wheel steer axle has been removed from the machine.
1/23438C Backhoe Loader Side Shift, Parallel Lift 1TR00001-01283 (MACHINE) POWE...
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NOTE: The left and right axle housing assemblies are identical. All operations covered in this
section must be performed on both the right and the left axle housing assemblies.
1. Secure axle assembly to tooling (A) prior to starting any work.
2. Loosen plug (1) in final drive and drain oil in suitable container.

3. Loosen two socket head bolts (2) and separate the planetary carrier (3) from hub (4). Attach
strap and remove carrier (3). Approximate weight is 34 kg (75 lb).
4. Remove snap ring (5).
5. Install tooling (B) and remove planetary gears (6).
6. Remove snap ring (7) and remove thrust washer (8).

7. Loosen both hex head screws (9) and remove lock plate (10).
8. Using tooling (C) loosen and remove slotted nut (11).
9. Separate internal gear (12) from steering knuckle housing (13).
10. Using tooling (D), separate hub (14) from steering knuckle housing (13).

11. Remove bearing (15), O-ring (16), and bearing race (17) from hub (14).
12. Turn hub (13) over and pry out seal ring (18) and remove bearing race (19) from bore of hub
(14).
13. Using tooling (C) remove bearing and bearing inner race (20) from steering knuckle housing
(13).
14. Remove snap ring (21).

15. Remove two thrust washers (22).
16. Measure the the distance (X) between the bottom of adjustment nut (23) and the top of bolt
(24). Record this measurement for assembly purposes and remove nut and bolt (23) and (24).
17. Remove cotter key (25) and loosen castle nut (26).
18. Install tooling (E) remove tie rod end (27) from bore.

19. Remove four bolts (28). Remove two plastic caps and install two forcing screws.
20. Attach suitable lifting device to steering knuckle housing. Apply pressure to forcing screws
and remove bearing and pin (29) using forcing screws.
21. Install forcing screws to the lower bearing and pin (30) and remove remove second bearing
and pin (30).

NOTE: It is important to note the placement of shims (33). Retain the proper shim with its
corresponding pin.
22. Separate bearing (31), O-ring (32), shims (33) from pin (29) or (30) on both the top and
bottom for both sides.
23. Remove steering knuckle housing (13) from the axle.
24. Remove seal (34) from steering knuckle housing bore.
NOTE: It may be necessary to destroy seal to remove it.
25. Remove bushing (35) from knuckle housing bore.
NOTE: The direction of the grooves in bushing (35) are important. The direction of these grooves
are important for proper lubrication of the axle shaft. It will be necessary to replace this bushing in
exactly the same manner.

26. Remove both bearing races (36) and (37) out of the axle housing.
27. Remove axle shaft and sun gear (38) with both universals from the axle housing.
28. Remove snap ring (39) from axle shaft (38).
NOTE: It may be necessary to destroy seal to remove it.

29. Remove seal (40) from axle housing.
NOTE: The direction of the grooves in bushing (35) are important. The direction of these grooves
are important for proper lubrication of the axle shaft. It will be necessary to replace this bushing
with the grooves in the same position.
30. Remove bushing (41) from axle housing.
31. Place alignment marks on the axle housing and the brake housing to insure proper assembly.
Attach suitable lifting device to axle housing (42). Remove sixteen bolts (43) and separate axle
housing (42) from the brake housing. Weight of axle housing is 86 kg (190 lb).
NOTE: It may be necessary to pry the axle housing from the brake housing. There is a locating
spring pin pressed into the mating surface of the brake housing
10/23438C Backhoe Loader Side Shift, Parallel Lift 1TR00001-01283 (MACHINE) POW...

32. Place alignment marks on bushing (43) located on the inside portion of axle housing (42).
Carefully remove bushing (43) from the two pins which hold it.
NOTE: The direction and position of the grooves in bushing (43) are important. The direction of
these grooves are important for proper lubrication. It will be necessary to replace this bushing in
exactly the same manner.
Assemble Final Drive And Axle (Rear) (All Wheel Steer)
Fluid Spillage Containment
Care must be taken to ensure that fluids are contained during performance of inspection,
maintenance, testing, adjusting and repair of the machine. Be prepared to collect the fluid with
suitable containers before opening any compartment or disassembling any component containing
fluids. Refer to "Tools And Shop Products Guide", NENG2500 for tools and supplies suitable to
collect and contain fluids in Caterpillar machines. Dispose fluids according to local regulations
and mandates.
NOTE: For photographic purposes, the all wheel steer axle has been removed from the unit.
NOTE: The left and right axle housing assemblies are identical. All operations covered in this
section must be performed on both the right and the left axle housing assemblies.
NOTE: For purposes of this assembly procedure only one side of the axle is being assembled. The
identical procedure must be performed to both right and left sides of the axle.

1. Using tooling (A), install sleeve (2) into center bore of axle housing (2). Drive sleeve into the
axle housing until it is flush with thestep in the axle housing.
NOTE: Prior to installation of sleeve (2), insure that the lubrication grooves are in the downward
position in relation to the axle. These grooves are critical for proper lubrication.

2. Using tooling (A), lubricate and install seal (3) and install it in the center bore of axle housing
(1). Apply some 9S3263 Threadlocker to the outer metal diameter of the seal.
3. Using tooling (B), install outer bearing race (4) into the upper and lower steering knuckle bore.
4. Install sun gear (5) and secure by means of snap ring (6).

5. Install dust shield (7) and bushing (8) to the axle shaft.
6. Install axle shaft (9) into axle housing (1).

7. Using tooling (A), install sleeve (10) into bore of steering knuckle hull (11)
NOTE: Prior to installation of sleeve (10), insure that the lubrication grooves are in the downward
position in relation to the axle. These grooves are critical for proper lubrication.
8. Using tooling (A), lubricate and install seal (12) and install it in the center bore of steering
knuckle hull (11). Apply some 9S3263 Threadlocker to the outer metal diameter of the seal.

9. Assemble upper and lower bearing pins (16) as follows:
a. Install O-ring (15) into groove located in pin (16) under seal cap (14).
b. Install seal cap (14) on pin (16) under bearing (13).
c. Place bearing (13) and assembled pin (16) in a press and press bearing (13) onto pin (16) until
contact is made.
10. Install tooling (C) to steering knuckle hull (11) and lift into position. Fit sun gear (5) portion of
axle shaft through center of steering knuckle hull (11). Insure that bushings and seals are not
dislodged during assembly.

11. Install original shim (17) under each of the upper pins (16) on each side of the axle. Test the
rolling torque of the steering knuckle hull. The rolling torque should be 23 to 30 N·m (17 to 22 lb
ft).
NOTE: If new bearings are used, installed properly, and a shim of 60mm (.02 in) is used the
proper rolling torque will be achieved.
NOTE: Check the final position of pin (16) prior to final torquing of the bolts. The lubricating
fitting should be facing the center of the axle.
12. Install the proper shim (17) and install pin (16). Install four bolts (18) and tighten to a torque
of 280 N·m (207 lb ft).
NOTE: Recheck rolling torque of steering knuckle hull (11) a final time to insure accuracy.
Lubricate all four bearings.

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13. Place hub (19) in a press and install bearing race (20) into the hub.
14. Turn hub (19) over in the press. Using tooling (E), press seal (21) into the hub.
NOTE: Apply some 9S3263 Threadlocker to the outer metal diameter of the seal.
15. Heat bearing (22) and install it onto steering knuckle hull until full contact is made.

16. Install O-ring (22) on hub (19). Lubricate seal (21) inside hub (19). Install assembled hub (19)
onto steering knuckle hull and retain in place with outer bearing (23).
17. Install internal gear (24) onto hub (19).
18. Install slotted nut (25). Insure that chamfered side of slotted nut (25) is facing outward.
19. Adjust the rolling torque of the bearings by use of a spring scale, tooling (F) and tooling (G).
20. Continue to turn hub by use of tooling (F) while at the same time tightening slotted nut (25)
with tooling (G). Rolling torque of the hub should be 27 to 46 N·m (20 to 34 lb ft).
NOTE: If new bearings were used the higher rolling torque value should be used. If bearings were
reused, the lower rolling torque value should be used.

21. After the proper rolling torque has been attained, install lock plate (26) and two bolts (27) to
secure slotted nut (25). Tighten bolts (27) to a torque of 69 N·m (51 lb ft).
NOTE: Use only new bolts (27) to secure lock plate (26). These bolts can only be properly torque
one time.
22. Install two washers (28) and (29) as shown. The stepped face of the outer washer (29) should
be facing outward.
23. Install snap ring (30) in the groove of the sun gear portion of the axle shaft. This snap ring will
secure washers (28) and (29).
24. Assemble three sets of planetary gears (31) as shown. Heat and install two sets of gears in
planetary gear carrier.
NOTE: It is possible to perform the following calculations with all three planetary gears installed
in the planetary carrier but very difficult. It is recommended that just two planetary gears be
installed at this time.
25. Calculate the end play of the sun gear portion of the axle shaft in the following manner.

a. Using a depth gauge and tooling (H) measure dimension (I) from the flange mounted surface to
the contact face of the thrust washer. Example Dimension (I) 166.20 mm.
NOTE: Remember to subtract for the thickness of tooling (H).
b. Tilt the drive 90 degrees to the steering axle of the axle housing and push the sun gear in. Using
a depth gauge and tooling (H), determine dimension (II) from the end face of the sun gear shaft to
the flange mounted surface of the hub. Example Dimension (II) 163.10 mm.
NOTE: Remember to subtract for the thickness of tooling (H).

Caterpillar cat 438 c backhoe loader (prefix 1tr) service repair manual (1tr00001 01283)

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Caterpillar cat 438 c backhoe loader (prefix 1tr) service repair manual (1tr00001 01283)