repair manual download

1. 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.
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3. 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).
Illustration 2 g03828843
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).
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4. Illustration 3 g03828844
7. Remove bolts (13) and solenoid valve (12) from transmission (2).
Illustration 4 g03828845
Illustration 5 g03828846
Personal injury can result from being struck by parts propelled by a
released spring force.
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5. 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).
Illustration 6 g03828847
Illustration 7 g03828848
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.
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6. 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).
Illustration 8 g03828849
Illustration 9 g03828850
12. Remove self-locking nut (24), O-ring seal (26) coil assembly (25), and O-ring seal (27)
from solenoid valve (12).
Illustration 10 g03828851
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7. Illustration 11 g03828852
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.
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).
Illustration 12 g03828876
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).
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8. Illustration 13 g03828878
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.
Illustration 14 g03828879
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
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9. Illustration 15 g03828880
1. Remove front output shaft (37).
Illustration 16 g03829476
Illustration 17 g03829477
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.
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10. 4. Remove roller bearing (42), spacer (43), roller bearing (44), needle bearing (45), and thrust
washer (46) from the shaft.
Illustration 18 g03829478
5. Remove retaining ring (47).
Illustration 19 g03829479
6. Remove plate (48).
Illustration 20 g03829480
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11. Illustration 21 g03829481
7. Remove friction disks (49) and friction clutches (50).
Illustration 22 g03829482
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. Use a suitable press and Tooling (C) to compress spring assembly (52). Use Tooling (D) to
remove retaining ring (51).
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12. Illustration 23 g03829483
9. Remove spring assembly (52) and retainer (53).
Illustration 24 g03829484
10. Release piston (54) by applying 207 kPa (30 psi) of air pressure into the lube passage as
indicated.
11. Remove seal ring (55).
Illustration 25 g03829485
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13. 12. Use Tooling (E) and a suitable press to remove bearing cone (56). Remove bearing cone
(56).
Direct Drive, Rear Output Shaft
Illustration 26 g03829593
Illustration 27 g03829664
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.
1. Remove plug (57), spring (59), and ball (58).
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14. Illustration 28 g03829665
Illustration 29 g03829668
2. Remove screws (60) from the shift forks. Remove rod (61) and ball (62).
Illustration 30 g03829669
Personal injury can result from being struck by parts propelled by a
released spring force.
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15. Make sure to wear all necessary protective equipment.
Follow the recommended procedure and use all recommended tooling to
release the spring force.
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).
Illustration 31 g03829670
Illustration 32 g03829671
Personal injury can result from being struck by parts propelled by a
released spring force.
Make sure to wear all necessary protective equipment.
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16. Follow the recommended procedure and use all recommended tooling to
release the spring force.
5. Remove plug (57), ball (67), and spring (66).
6. Remove rear output shaft (65).
Illustration 33 g03829672
Illustration 34 g03829763
7. Remove screw (69) and washer (68).
8. Use Tooling (F) and a suitable press to remove bearing cone (70) and gear (71).
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17. Illustration 35 g03829764
9. Remove needle bearings (72) and (73).
10. Use Tooling (D) to remove lock ring (74).
Illustration 36 g03829765
11. Remove synchronizer assembly (75).
Illustration 37 g03829811
12. Remove sleeve (76).
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18. Illustration 38 g03829766
13. Remove gear (77).
Illustration 39 g03829767
14. Remove needle bearings (78) and (79).
Illustration 40 g03829768
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20. Illustration 41 g03829812
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
Illustration 42 g03830710
1. Remove direct drive shaft (93).
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21. Illustration 43 g03830711
2. Use Tooling (F) and a suitable press to remove bearing cone (94). Remove bearing cone
(94).
Illustration 44 g03830712
3. Use Tooling (E) and a suitable press to remove bearing cone (95). Remove bearing cone
(95).
Direct Drive, Reverse Shaft
Illustration 45 g03830819
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22. 1. Remove reverse shaft (96).
Illustration 46 g03830821
2. Remove ring seals (97).
Illustration 47 g03830822
Illustration 48 g03830824
3. Use Tooling (G) to remove bearing cone (98). Remove bearing cone (98), thrust washer
(100), bearing (101), and gear (99).
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23. Illustration 49 g03830825
4. Remove needle bearing (102) and thrust washer (103).
Illustration 50 g03830827
5. Remove retaining ring (104) and end plate (105).
Illustration 51 g03830829
6. Remove clutch pack (106).
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