Caterpillar cat 438 d backhoe loader (prefix bpn) service repair manual (bpn00476 00549)

Service Repair Manual
Model
438D BACKHOE LOADER

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Product: BACKHOE LOADER
Model: 438D BACKHOE LOADER BPN
Configuration: 438D Backhoe Loader BPN00476-00549 (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
i02557470
Transmission (Power Shift) - Disassemble
SMCS - 3030-015-PM; 3066-015
Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 1U-7502 Repair Stand 1
B
152-7085 (1)
Transmission Shaft Handler 1
189-0409 Shackle As 1
C 1P-0074 Slide Hammer 1
D
8H-0063 Bearing Puller Assembly 1
6V-3010 Puller Group 1
126-7177 Leg 2
E 1U-6405 Puller 1
F 152-7055 Spring Compressor 1
G 1U-6400 Puller 1
H
128-5041 Bearing Puller 1
6V-3010 Puller Group 1
126-7177 Leg 2
I 6V-2157 Link Bracket 1
1/46438D Backhoe Loader BPN00476-00549 (MACHINE) POWERED BY 3054 Engine(...
2019/10/1https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

( 1 )
CE Compliant
Start By:
A. Remove the transmission. Refer to Disassembly and Assembly, "Transmission (Powershift)
- Remove".
NOTICE
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting and repair
of the product. Be prepared to collect the fluid with suitable containers
before opening any compartment or disassembling any component
containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer Service
Tool Catalog" for tools and supplies suitable to collect and contain
fluids on Caterpillar products.
Dispose of all fluids according to local regulations and mandates.
Note: Cleanliness is an important factor. Before the disassembly procedure, the exterior of the
component should be thoroughly cleaned. This will help to prevent dirt from entering the internal
mechanism.
Note: The transmission will be disassembled in major components. The major components will
then be disassembled.
Illustration 1 g00730318
1. Use a suitable lifting device in order to install transmission (1) on tooling (A) . The weight
of transmission (1) is 172 kg (379 lb).

2. Remove two valve groups (2) .
3. Remove nut (3) , washer (4) , and coil assembly (5) . Remove seal kit (6) from cartridge
(7) .

4. Remove magnetic sensor (8) .
5. Remove tube assembly (9) .

6. Remove valve group (10) .
7. Remove O-ring (11) and O-ring (12) .

9. Remove two O-rings (14) and O-ring (15) .
10. Remove two bolts (16) and plate (17) .
11. Remove O-ring (18) .

12. Remove screen filter (19) .
13. Remove oil filter (20) .
14. Remove two bolts (21) and elbow assembly (22) .

15. Remove two O-rings (23) .

17. Remove ball (25) , spring (26) , and O-ring (27) .
18. Remove pump drive shaft (28) from the transmission.
19. Remove bolt (29) , washer (30) , and yoke assembly (31) from the output shaft.

20. Remove gasket (32) from yoke (33) .
21. Remove bolt (34) and washer (35) .
22. Remove O-ring (36) and yoke (37) from the output shaft.
10/46438D Backhoe Loader BPN00476-00549 (MACHINE) POWERED BY 3054 Engin...

23. Remove four bolts (38) , washers (39) , and pump group (40) .
24. Remove seal (41) .

25. Remove lip seal (42) from pump group (40) .
26. Use tooling (I) and a suitable lifting device in order to support the transmission case.
Remove eighteen bolts (43) .
27. Use a pry bar in the slots of the transmission case in order to break the seal. Carefully
remove case assembly (44) . The weight of case assembly (44) is 26.9 kg (59 lb).

28. Remove lip seal (45) from case assembly (44) .
29. Remove tube assembly (46) and (47) from case assembly (44) .
30. Remove bearing cups (48) , (49) , and (50) from case assembly (44) .

Note: Record the measurement of shims (51) to aid in installation.
31. Remove shims (51) from case (44) .
32. Remove output shaft (52) .

33. Use Tooling (B) , washer (35) , and bolt (34) in order to remove rear output shaft (53) , shaft
(54) , and input shaft (55) . The combined weight of rear output shaft (53) , shaft (54) , and
input shaft (55) is 61.3 kg (135 lb).
34. Remove reverse shaft (56) from the case assembly.
35. Use tooling (C) in order to remove bearing cups (57) .

36. Remove lip seal (58) from the case assembly.
37. Remove tube assembly (59) .
Output Shaft (Front)

1. Remove ring (60) from front output shaft (52) .
2. Use tooling (D) in order to remove bearing cone (61) .

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3. Use tooling (E) in order to remove spacer (62) , bearing cone (63) , washer (64) , needle
thrust bearing (65) , and gear (66) .
4. Remove caged roller bearing (67) , spacer (68) , caged roller bearing (69) , needle thrust
bearing (70) , and washer (71) .
5. Remove retaining ring (72) and end plate (73) .

6. Remove eight friction discs (74) and eight plates (75) .
7. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (76) .
8. Remove spring assembly (77) .

9. Use shop air in order to remove piston assembly (79) , as shown.
10. Remove ring (78) and the O-ring from piston (79) .
Output Shaft (Rear)

1. Remove rings (80) and (81) .
2. Use tooling (G) in order to remove bearing cone (82) , washer (83) , needle thrust bearing
(84) , caged roller bearing (85) , and gear (86) .

3. Remove caged roller bearing (87) , needle thrust bearing (88) , and washer (89) .
4. Remove retaining ring (90) and end plate (91) .

Caterpillar cat 438 d backhoe loader (prefix bpn) service repair manual (bpn00476 00549)

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