Caterpillar cat 438 c backhoe loader (prefix 2dr) service repair manual (2dr00001 02716)

Service Repair Manual
Model
438C BACKHOE LOADER

Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 438C BACKHOE LOADER 2DR
Configuration: 438C Backhoe Loader Side Shift, Parallel Lift 2DR00001-02716 (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
SENR12060008
Axle Housing (Front) (All Wheel Drive)
SMCS - 3260-016; 3260-015
Disassemble Axle Housing (Front) (All Wheel Drive)
Start By:
a. remove final drive planetary carrier hub
1/12438C Backhoe Loader Side Shift, Parallel Lift 2DR00001-02716 (MACHINE) POWE...
2019/10/9https://127.0.0.1/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sis...

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: Front axle removed for better photographic illustration
1. Remove eight bolts (1).
2. Remove internal gear (2) using Tooling (A).
3. Remove hub (3) from steering housing hub (4) using Tooling (B).

4. Pry shaft seal (5) out of hub (3). If necessary, drive the two bearing outer races out of the hub
bores.
5. Remove bearing inner race from the axle housing hub (4) using Tooling (C) and Tooling (D).
6. Loosen nut (9), but do not remove from tie rod (10).
7. Push tie rod (10) out of the axle housing hub (4) using Tooling (E).
8. Remove nut (9) from tie rod (10).

9. Remove bolts (11) and king pins (12) from the top and bottom of axle housing hub (4).
10. Remove shim (13) from top king pin.
NOTE: Check king pin bearings and if needed replace them using the following procedure:

a. Press bearing inner race (14) and shaft seal (15) from the king pin using Tooling (F).
b. Press shaft seal (15) and bearing inner race (14) on the king pin using Tooling (G).
11. Attach hoist and pull complete axle housing hub (4) along with double-joint shaft (16) out of
the axle housing (17(.

12. Remove retaining ring (18) and separate double-joint shaft (16) from the axle housing hub (4).
13. Expand retainer ring (19) and separate sun gear (20) from the double-joint shaft (16).
14. Pull shaft seal (21) out of the axle housing hub (4) using Tooling (H).
15. Press sleeve and shield (22) from the double-joint shaft (16) using Tooling (F).
16. Remove the two bearing outer races out of the axle housing bores using Tooling (H).

17. Pull out shaft seal using Tooling (H).
18. Pull sleeve out of the bore using Tooling (J).
Assemble Axle Housing (Front) (All Wheel Drive)
and mandates.
NOTE: Front axle removed for better photographic illustration

1. Drive sleeve in axle housing using Tooling (A).
2. Drive shaft seal, seal lip facing the oil chamber against shoulder using Tooling (B).
3. Insert the two bearing outer races in the steering housing bores until contact is obtained using
Tooling (C).
4. Press ball bearing in the bore of the axle housing hub until contact is obtained.

5. Install the retainer ring.
6. Press shaft seal with the sealing lips facing the ball bearing until seated using Tooling (D).
7. Insert shield and shaft seal in the bore of the steering housing.
8. Install sun gear (3) in double-joint (1) and install retainer ring (2).

9. Assemble shield (5) and heated sleeve (4) upon double-joint (1) and place them against
shoulder.
10. Install pre-assembled double-joint shaft (1) in the axle housing hub (6).
12. Install retainer ring to secure in double joint-shaft using Tool (E).
13. Install steering housing hub (6) with double-joint shaft in the axle housing until the double-
joint shaft splines are seated in the side gear.
14. Install 0.08 mm (.003 in) shim (7) and king pin (8) in the top of steering housing hub (6) and
install king pin without shim in the bottom of the steering housing hub.
15. Install bolts and tighten to a torque of 117 N·m (86 lb ft).
10/12438C Backhoe Loader Side Shift, Parallel Lift 2DR00001-02716 (MACHINE) PO...

16. While moving the steering housing back and forth use a torque wrench to check the rolling
resistance. The rolling resistance should be 18 to 20 N·m (13 to 15 lb ft). If the rolling resistance
is more than the specified value, remove shim (7) and replace it with a thicker shim. If the rolling
resistance is less than the specified value, remove shim (7) and replace it with a thinner shim.
17. Press both bearing outer races firmly against shoulder using Tool (F).
18. Press in the shaft seal with the words out side outwards (on top) until it is flush using Tool (G).
19. Assemble heated bearing inner race (9) upon the axle housing hub (6) until contact is obtained.
20. Assemble pre-assembled hub (10) to the steering housing (6) and fix it by means of heated
bearing inner race (11).

21. Assemble internal gear (12) and install bolts (13). Tighten bolts (13) to the torque of 68 N·m
(51 lb ft).
End By:
a. install fine drive planetary carrier hub
Copyright 1993 - 2019 Caterpillar Inc.
All Rights Reserved.
Private Network For SIS Licensees.
Wed Oct 9 07:32:07 UTC+0800 2019

Shutdown SIS
Previous Screen
Product: BACKHOE LOADER
Model: 438C BACKHOE LOADER 2DR
Configuration: 438C Backhoe Loader Side Shift, Parallel Lift 2DR00001-02716 (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 - 4050-016; 4050-015
Disassemble Final Drive And Axle Housing (Rear) (All Wheel
Steer)
and mandates.
NOTE: For photographic purposes, the all wheel steer axle has been removed from the machine.

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).

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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.

Caterpillar cat 438 c backhoe loader (prefix 2dr) service repair manual (2dr00001 02716)

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Caterpillar cat 438 c backhoe loader (prefix 2dr) service repair manual (2dr00001 02716)