Caterpillar Cat 438D BACKHOE LOADER (Prefix BPE) Service Repair Manual (BPE00001-00663).pdf

Service Repair Manual
Model
438D BACKHOE LOADER

Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 438D BACKHOE LOADER BPE
Configuration: 438D Backhoe Loader BPE00001-00663 (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
i01381641
Transmission (Direct Drive) - Assemble
SMCS - 3030-016-DD; 3066-016
Assembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 137-8102 Spring Compressor 1
B 1P-1859 Snap Ring Pliers 1
C 4C-3652 Spring Compressor 1
D 6V-2157 Link Bracket 1
E 8T-5096 Indicator 1
F 1U-5750 Engine Stand 1
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.
Transmission case
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Illustration 1 g00729262
Note: Install the shims behind each bearing cup that was recorded on the disassembly
procedure.
1. Install bearing cups (60), (61), (62), (63), and (64) .
(Direct Drive) Input Shaft
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.
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2. Install the seals on piston (56) .
3. Install piston (56). Install the retainer and spring (55). Use tooling (A) and a suitable press
in order to compress spring (55). Use tooling (B) in order to install snap ring (54) .
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4. Install clutch pack (53) and retainer (52) .
5. Repeat Steps 2 through 4 for the opposite end of the input shaft.
6. Install gear (51), needle bearing (50), and spacer (49). Use tooling (B) in order to install
snap ring (48) .
7. Heat bearing cone (57) to 135 °C (275 °F). Install bearing cone (57) .
8. Install the input shaft.
(Direct Drive) Reverse Shaft
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1. Heat bearing cones (45) and (46) to 135 °C (275 °F). Install bearing cones (45) and (46) .
2. Install the reverse shaft.
(Direct Drive) Shaft
1. Heat bearing cones (45) and (46) to 135 °C (275 °F). Install bearing cones (45) and (46) .
2. Install the shaft.
(Direct Drive) Output Shaft (Rear)
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1. Install gear (42) .
2. Install housing (41) and gear (40). Use tooling (B) in order to install snap ring (39) .
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3. Install synchronizer (38). Install gear (37). Heat bearing cone (36) to 135 °C (275 °F).
Install bearing cone (36) .
4. Install synchronizer (35), spacer (34), and bearings (33) .
5. Install gear (31) and (32). Heat bearing cone (30) to 135 °C (275 °F). Install bearing cone
(30) .
6. Install the output shaft (rear) in the transmission.
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7. Install two gearshift rods (23) on shift forks (29). Install the gearshift rods in the
transmission. Install three balls (28), two springs (27), and O-ring (26). Install plug (25) .
8. Install screws (24) on each of the gearshift rods (23) .
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(Direct Drive) Output Shaft (Front)
1. Install seals on piston (22) .
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2. Install piston (22), spring (19), and retainer (21) .
3. Use tooling (C) and a suitable press in order to compress spring (19). Use tooling (B) in
order to install snap ring (20) .
4. Install clutch pack (18) and retainer (17) .
5. Install thrust washer (16), needle bearing (15), spacer (14), and two roller bearings (13) .
10/14
438D Backhoe Loader BPE00001-00663 (MACHINE) POWERED BY 3054 Engin...
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8. Install front output shaft (9) .
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Final Assembly
Note: Clean the mating surfaces of case (7). Apply a continuous bead of 1U-8846 Sealant to
the mating surface of the case.
1. Attach tooling (D) to case (7). Attach a suitable lifting device to tooling (D). Use fourteen
bolts (8) in order to install case (7). The weight of case (7) is 42 kg (94 lb).
2. Install a bolt in the output shaft. The output shaft must be fully seated. Install tooling (E), as
shown. Zero tooling (E). Pry up on the bolt and record the reading on tooling (E). The
reading must be 0.03 mm (0.0012 inch) to 0.08 mm (0.0031 inch). Add or remove shims in
Step 1 in the Case Assembly Procedure in order to obtain the correct reading.
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3. Repeat Step 1 for the input shaft and the output shaft (front). Use the same tolerance for all
of the shafts. Remove the expansion plug in order to check the input shaft. Use a
screwdriver to pry up on the input shaft. Install a new 1H-9721 Expansion Plug .
4. Install yoke (4), washer (5), and bolt (6) .
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5. Install plug (3) .
6. Install Implement pump drive shaft (2) in transmission (1) .
7. Remove transmission (1) from tooling (F) .
End By: Install the transmission. Refer to Disassembly and Assembly, "Transmission (Direct
Drive) - Install".
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Oct 3 12:30:10 UTC+0800 2019
14/14
2019/10/3

Shutdown SIS
Previous Screen
Train
i01459029
Transmission (Direct Drive) - Install
SMCS - 3030-012-DD
Installation Procedure
Table 1
Required Tools
A
8S-7640 Stand 2
8S-7611 Tube 2
8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmisson Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar Assembly 1
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1. Attach tooling (D) to tooling (C) and transmission (10) in order to maintain a good balance.
2. Use tooling (C) in order to position transmission (10). The weight of transmission (10) is
185 kg (408 lb).
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3. Install fourteen bolts (11) .
4. Slide rod assembly (9) on the transmission lever and tighten bolt (8) .
5. Connect three electrical connectors (7) .
3/5
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6. Install four bolts (5) .
7. Repeat Step 6 for the opposite side.
8. Install two bolts (6) .
9. Install plug (4) .
10. Remove tooling (E). Install inspection plate (3) .
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11. Remove tooling (B) from front axle (2) .
12. Remove tooling (A) from rear frame (1) .
13. Fill the transmission with oil. Refer to Operation and Maintenance, SEBU7398,
"Capacities" for the proper type and capacity of oil.
,
End By:
a. Install the piston pump. Refer to Disassembly and AssemblyRENR3585, "Piston Pump
(Implement and Steering) - Install".
b. Install the rear drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Rear) -
Remove and Install".
c. Install the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) -
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Thu Oct 3 12:31:06 UTC+0800 2019
5/5
2019/10/3

Shutdown SIS
Previous Screen
Train
i05395070
Transmission (Power Shift) - Remove
SMCS - 3030-011-PM
Removal Procedure
Table 1
Required Tools
A
8S-7640 Stand 2
8S-7611 Tube 2
8S-7615 Pin 2
B 1U-9760 Jack Stand 2
C 1U-7505 Transmisson Jack 1
D 1U-7558 Mounting Brackets 2
E FT-2535 Engine Support Bar Assembly 1
Start By:
A. Remove the front drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Front) -
B. Remove the rear drive shaft. Refer to Disassembly and Assembly, "Drive Shaft (Rear) -
C. Remove the piston pump. Refer to Disassembly and Assembly, RENR3585, "Piston Pump
(Implement and Steering) - Remove".
1. Use a suitable lifting device in order to raise the machine to a height of 91.4 mm (36 inch)
between the ground and the side step.
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2. Place tooling (A) under rear frame (1) .
3. Place tooling (B) under front axle (2) .
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4. Remove the inspection cover. Install Tooling (E) in order to support the engine when the
transmission is removed.
5. Disconnect seven electrical connectors (3) . Cut three straps (4) .
6. Cut the strap and disconnect three electrical connectors (5) .
3/6
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Caterpillar Cat 438D BACKHOE LOADER (Prefix BPE) Service Repair Manual (BPE00001-00663).pdf

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