The document provides disassembly instructions for a transmission (power shift) on a 442D backhoe loader. It lists 30 steps to fully disassemble the transmission into its major components and sub-assemblies. These include removing valve groups, shafts, seals, gears, plates, bearings and other internal parts. Detailed illustrations accompany each step to show how to remove the individual components. Special tools are required to properly disassemble the transmission.
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Product: BACKHOE LOADER
Model: 442D BACKHOE LOADER BRY
Configuration: 442D Backhoe Loader BRY00747-00890 (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
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3. ( 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).
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4. Illustration 2 g00730319
2. Remove two valve groups (2) .
Illustration 3 g00730320
3. Remove nut (3) , washer (4) , and coil assembly (5) . Remove seal kit (6) from cartridge
(7) .
Illustration 4 g00730321
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9. Illustration 16 g00730334
15. Remove two O-rings (23) .
Illustration 17 g00730336
16. Remove valve group (24) .
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10. Illustration 18 g00730337
17. Remove ball (25) , spring (26) , and O-ring (27) .
Illustration 19 g00730338
18. Remove pump drive shaft (28) from the transmission.
Illustration 20 g00730340
19. Remove bolt (29) , washer (30) , and yoke assembly (31) from the output shaft.
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11. Illustration 21 g00730342
20. Remove gasket (32) from yoke (33) .
Illustration 22 g00730343
21. Remove bolt (34) and washer (35) .
Illustration 23 g00730344
22. Remove O-ring (36) and yoke (37) from the output shaft.
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12. Illustration 24 g00730345
23. Remove four bolts (38) , washers (39) , and pump group (40) .
Illustration 25 g00730348
24. Remove seal (41) .
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13. Illustration 26 g00730349
25. Remove lip seal (42) from pump group (40) .
Illustration 27 g00730350
26. Use tooling (I) and a suitable lifting device in order to support the transmission case.
Remove eighteen bolts (43) .
Illustration 28 g00730351
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).
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14. Illustration 29 g00730353
28. Remove lip seal (45) from case assembly (44) .
Illustration 30 g00730354
29. Remove tube assembly (46) and (47) from case assembly (44) .
Illustration 31 g00730355
30. Remove bearing cups (48) , (49) , and (50) from case assembly (44) .
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15. Illustration 32 g00730356
Note: Record the measurement of shims (51) to aid in installation.
31. Remove shims (51) from case (44) .
Illustration 33 g00730357
32. Remove output shaft (52) .
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16. Illustration 34 g01280623
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).
Illustration 35 g00730359
34. Remove reverse shaft (56) from the case assembly.
Illustration 36 g00730360
35. Use tooling (C) in order to remove bearing cups (57) .
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17. Illustration 37 g00730362
36. Remove lip seal (58) from the case assembly.
Illustration 38 g00730363
37. Remove tube assembly (59) .
Output Shaft (Front)
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18. Illustration 39 g00730365
1. Remove ring (60) from front output shaft (52) .
Illustration 40 g00730366
2. Use tooling (D) in order to remove bearing cone (61) .
Illustration 41 g00730368
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19. Illustration 42 g00730369
3. Use tooling (E) in order to remove spacer (62) , bearing cone (63) , washer (64) , needle
thrust bearing (65) , and gear (66) .
Illustration 43 g00730370
4. Remove caged roller bearing (67) , spacer (68) , caged roller bearing (69) , needle thrust
bearing (70) , and washer (71) .
Illustration 44 g00730371
5. Remove retaining ring (72) and end plate (73) .
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21. Illustration 45 g00730372
6. Remove eight friction discs (74) and eight plates (75) .
Illustration 46 g00730375
7. Use tooling (F) in order to compress the spring assembly. Remove retaining ring (76) .
Illustration 47 g00730376
8. Remove spring assembly (77) .
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22. Illustration 48 g00730378
9. Use shop air in order to remove piston assembly (79) , as shown.
Illustration 49 g00730379
10. Remove ring (78) and the O-ring from piston (79) .
Output Shaft (Rear)
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23. Illustration 50 g00730381
1. Remove rings (80) and (81) .
Illustration 51 g00730382
Illustration 52 g00730553
2. Use tooling (G) in order to remove bearing cone (82) , washer (83) , needle thrust bearing
(84) , caged roller bearing (85) , and gear (86) .
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24. Illustration 53 g00730554
3. Remove caged roller bearing (87) , needle thrust bearing (88) , and washer (89) .
Illustration 54 g00730555
4. Remove retaining ring (90) and end plate (91) .
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25. Illustration 55 g00730556
5. Remove eight friction discs (92) and eight plates (93) .
Illustration 56 g00730557
6. Use tool (F) in order to compress the spring assembly. Remove retaining ring (94) .
Illustration 57 g00730558
7. Remove spring assembly (95) .
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26. Illustration 58 g00730559
8. Use shop air in order to remove piston assembly (96) .
Illustration 59 g00730560
9. Remove seal (97) and the O-ring from piston (98) .
Illustration 60 g00730564
10. Use tooling (H) in order to remove bearing cone (99) .
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