Service Information SystemTuesday, April 12, 20165:53 PM Disassembly and Assembly 416B, 426B, 428B, 436B & 438B BACKHOE LOADERS POWER TRAIN

Media Number -SENR5803-03 Publication Date -01/08/2004 Date Updated -23/04/2013

SENR58030015

TransmissionSMCS - 3060-015; 3060-016

Disassemble TransmissionView Image

Start By: a. remove transmissionb. remove torque converter

NOTE: For organization and clarity purposes, the transmission will be disassembled into major components and then those components disassembled.Disassmble the transmission as follows:

1. Install the transmission onto tooling (A).View Image

2. Remove drain plug (1) and drain the transmission oil into a suitable container.View Image

3. Remove six bolts (2). Remove control valve assembly (3) and gasket.View Image

4. Using tooling (A), rotate the entire transmission.View Image

5. Remove yoke bolt and yoke (4).View Image

6. Remove three bolts (5). Remove control assembly (6) with anti-rotation pin (7). Remove lower seating and O-ring.

NOTE: Use care when removing the control assembly to insure that anti-rotation pin (7) does not slip out during removal. View Image

7. Remove eleven bolts and remove rear cover (9) and gasket (10).View Image

8. Remove countershaft and output shaft shim packs (11). Use a piece of wire of tape to keep each of the shim packs separate from the other. Label each of the shim packs to insure that it is reassembled properly.

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9. Remove lockscrew (13) then remove shift lugs (12).View Image

10. Remove two bolts and remove interlock plate (14). Remove two interlock balls (15) using a suitable magnet.

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11. Engage two gears by taping down shaft rods (16).

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12. Remove reverse idler nut (18), washer (17) and gear (19).View Image

13. Install tooling (B) to rear case (20). Using a soft metal drift, tap the idler shaft to free the spline, then remove fifteen bolts and remove rear case (20) and gasket (21). Also remove bearing (not shown). Weight of rear case is 34 kg (75 lb).

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14. Remove idler pinion, bearing and spacer (22). Also remove any remaining bearing shells.View Image

15. Flatten the lock tabs, remove one bolt (23) and remove suction pipe (24).View Image

16. Lift and tilt countershaft (26) and remove input shaft assembly (25). After this is completed return countershaft (26) to its original position.

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17. Remove two detent plugs (29), springs (28) and balls (27).View Image

18. Lift and tilt countershaft (26) and then remove output shaft (30) and shift fork assembly (31).View Image

19. Remove countershaft (26) from the transmission case.View Image

20. Remove shifting forks and rods (31).NOTE: If the forks are removed from the rods, clearly mark each so that it can be put back in the same position during reassembly. View Image

21. Remove oil feed pipe (32).View Image

22. Remove eight bolts (33) and remove front wheel drive unit (34) and gasket. Weight of front wheel drive unit (34) is 34 kg (75 lb).

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23. Remove two bolts (35) and oil filter housing (36).View Image

24. Remove two bolts (37) and oil strainer retaining plate (38), O-ring (39) and oil strainer (40).View Image

25. Install tooling (B) as shown and remove eight bolts (41) and remove converter housing (42).View Image

26. Remove four bolts and washers (43) and remove oil pump and sealing ring (not shown).View Image

27. Remove three bearing races (45).Disassemble the transmission oil pump as follows: NOTE: The oil pump can be disassembled if any form of contamination was present in the transmission. Disassembly of the oil pump however, is not generally recommended since individual components are nonservicable. If a major transmission overhaul is required, the oil pump should be cleaned or if necessary replaced. View Image

1. Remove drive gear (1) from torque converter coupling (2).View Image

2. Remove gear (3).View Image

3. Remove oil seal (4).Disassemble the transmission countershaft as follows: View Image

1. Using tooling (C) and a press, remove gear (2) and bearing (1).View Image

2. Turn the countershaft over and install tooling (C) and a press. Remove bearing (3).Disassemble the transmission input shaft as follows: View Image

1. Remove seal rings (1).View Image

2. Install tooling (D) and remove rear bearing (2).View Image

3. Remove washer (3), thrust disc (4) and anti-rotation pin (5).View Image

4. Remove reverse primary gear (6).View Image

5. Remove bearings (7), washer (8) and anti-rotation pin (9).View Image

6. Remove spring retainer (10) and retainer (11) and clutch plates (12).View Image

7. Install tooling (E). Remove snap ring (13). Using tooling (E), compress spring pack (14).

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8. Remove spring pack (14).View Image

9. Turn the shaft assembly over and remove sealing ring (16).View Image

10. Install tooling (G) and remove bearing (17).View Image

11. Remove washer (18), disc (19) and anti-rotation pin (20).View Image

12. Remove forward primary gear (21).View Image

13. Remove bearing (22), washer (23) and anti-rotation pin (24).View Image

14. Remove retaining ring (25), retainer (26) and clutch plates (27).View Image

15. Using tooling (H), remove snap ring (28).NOTE: Do not reuse snap ring (28). View Image

16. Remove spring assembly (29).

Always wear protective eye wear when using compressed air. Insure that the air nozzle has been reduced in pressure to comply with OSHA regulations.

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17. Using a suitable source of compressed air and the proper approved nozzle, force air into the hydraulic ports. Remove the forward piston and then the reverse piston.

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18. Remove center seal (30) and outer seal (31) from piston (32).Disassemble the transmission output shaft as follows: View Image

1. Position the shaft vertically. Using tooling (D), remove bearing (1) and the spacer below it.View Image

2. Remove drive gear (2) and first gear (3).View Image

3. Remove two bearings (4) and spacer (5).View Image

4. Remove first and second gear synchronizer assembly (6).View Image

5. Using tooling (F) under second gear (9), remove first gear bearing sleeve (7), synchronizer sleeve (8) and second gear (9).

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6. Turn the shaft over and using tooling (D), remove bearing (10).View Image

7. Remove fourth gear (11). Remove third and forth gear synchronizer.View Image

8. Remove snap ring (13). Remove third and fourth gear synchronizer sleeve (14).View Image

9. Remove third gear (15).Disassemble the transmission control valve as follows: NOTE: This control valve is used on the following models and serial numbers: 416B 8SG1-UP, 8ZK1-UP, 426B 5YJ1-UP, 6KL1-UP 428B 7EJ1-UP 436B 6MJ1-UP, 7FL1-UP 438B 3KK1-UP. View Image

1. Remove solenoid (1), seal (2), spool (3) and spring (4).View Image

2. Remove plug and seal (7), three springs (6) and spool (5).View Image

3. Remove plug and seal (10), spring (9) and ball (8).View Image

4. Remove switch and seal (11) and three balls (12).

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5. Remove plug and seal (14) and spool (13).View Image

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NOTE: Examine selector assembly (16) carefully prior to disassembly. Disassemble only if necessary. Assembly is difficult.

6. Remove snap ring (15).7. Remove selector assembly (16) and seal (17).8. Remove detent ball (19) and spring (18).

Disassemble the transmission hydraulic four wheel drive as follows: NOTE: This control valve is used on the following models and serial numbers: 416B 8SG1-UP, 8ZK1-UP, 426B 5YJ1-UP, 6KL1-UP 428B 7EJ1-UP 436B 6MJ1-UP, 7FL1-UP 438B 3KK1-UP. View Image

1. Flatten the tab washer and remove bolt (1). Remove washer (2) and output coupling (3).View Image

2. Remove four bolts (4), cover (5) and gasket (not shown).View Image

3. Remove spacer (6) and shims (7).View Image

4. Remove four wheel drive assembly over and flatten tab washer and remove nut (8) and washers.

NOTE: It will be necessary to secure the shaft to remove nut (8) from shaft. View Image

5. Remove solenoid (9), spool (10), and spring (11).View Image

6. Remove four bolts (12). Remove control housing (13) and O-rings (14).View Image

7. Remove sleeve (15) and O-ring seal (16).View Image

8. Install four wheel drive assembly in a press and remove output shaft and bearing (17).NOTE: If lower bearing does not stay on the shaft when the shaft is removed from the case, remove lower bearing from the case. View Image

9. Remove gear (22), (23) and (24), bearings (29), washers (26), (27), (28), clutch plates (25), cover (20) and spring pack (21).

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10. Remove seal rings (30) from sleeve (15).View Image

11. Remove all remaining O-rings (31) and seal ring (32) from piston (33).View Image

12. Remove O-ring (34) from cylinder (20).

Assemble TransmissionView Image

Assemble the transmission oil pump as follows: NOTE: For organization and clarity purposes, the transmission will be assembled into major components and then those components assembled into the finished transmission. View Image

1. Install oil seal (4).View Image

2. Install gear (3).View Image

3. Install drive gear (1) into the torque converter housing.Assemble the countershaft as follows: View Image

1. Heat bearing (3) to a temperature of 275°F and install bearing on countershaft (2).View Image

2. Turn countershaft (2) over. Heat bearing (1) to a temperature of 275°F and install it on countershaft (2).

Assemble the input shaft as follows: View Image

1. Replace O-rings (30). Replace seal (31) on piston (32). Prior to installing seal (31), soak seal (31) in warm water. This will make the seal flexible and prevent cracking or distortation.

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2. Using tooling (J), to compress seal (31). Leave seal (31) in tooling (J) for approximately 30 minutes. This will compress the seal enough so that it will easily install into the drum clutch without damage. Remove piston (32) with the seal and install into the forward side of the clutch drum. Turn the clutch drum over and repeat the procedure with the reverse piston.

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3. Install spring pack (29). Using tooling (H), secure the spring pack with a new snap ring (28).View Image

4. Install anti-rotation pin (24) and thrust washer with the oil grooves facing up.View Image

5. Install forward gear bearings (22) and gear (21).View Image

6. Install anti-rotation pin (20). Install plastic washer (19) with the boss located inside the plastic washer. Install the metal washer (18).

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7. Install clutch pack (27) starting with a plate and alternating between plate and disc.

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8. Install retainer (26) as shown with the recess upward. Secure with snap ring (25).View Image

9. Heat bearing (17) to a temperature of approximately 275°F and install on shaft. It may be necessary to use to use the appropriate sleeve and press bearing (17) into place. Install seal ring (16).

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10. Using tooling (E), install spring pack (14) and secure a new snap ring (13).View Image

11. Install anti-rotation pin (9) and thrust washer (8) with oil grooves facing upward.View Image

12. Install reverse gear bearing (7) and gear (6).View Image

13. Install anti-rotation pin (5), plastic washer (4) and metal washer (3).View Image

14. Install clutch pack (12) starting with a plate and alternating between plate and disc.View Image

15. Install retainer (11) as shown with the recess upward and secure with snap ring (10).View Image

16. Heat bearing (2) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (2) into place.

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17. Install seal rings (1).Assemble the transmission output shaft as follows: View Image

1. Install third gear (15) as shown with teeth of smaller portion of gear facing upward.View Image

2. Install synchronizer (14) and snap ring (13).View Image

3. Install third and fourth gear synchronizer (12) with the extended cup facing upward.4. Install fourth gear (11) with teeth of smaller portion of the gear facing upward.

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5. Heat bearing (10) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (10) into place.

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6. Turn the shaft over and install second gear (9) as shown, with teeth of smaller portion of gear facing upward. Install first and second gear synchronizer (8).

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7. Heat bearing (7) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (7) into place.

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8. Install the first and second gear synchronizer assembly (6). Install first gear bearings (4) and spacer (5).

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9. Install first gear (3). Install first gear (3) as shown with teeth of smaller portion of gear facing downward.

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10. Replace drive gear (2) with oil grooves facing down.View Image

11. Heat bearing (11) to a temperature of approximately 275°F and install on shaft. It may be necessary to use the appropriate sleeve and press bearing (1) into place.

Assemble the transmission as follows: View Image

1. Replace the seal ring (3) between oil pump (1) and transmission housing (4). Install four bolts and washers (2) securing oil pump and tighten to a torque of 17 to 31 N·m (13 to 23 lb ft).2. Install the torque converter housing and secure with bolts. Tighten to a torque of 83 to 111 N·m (60 to 80 lb ft).

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3. Turn the transmission housing over and replace three front bearing races (5), (6) and (7). Insure that each race is totally seated.

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4. Install oil feed pipe (8). Secure pipe (8) using two special bolts (9). Use 9S3263 Threadlocker on the threads of bolts (9) and tighten to a torque of 34 to 41 kg (25 to 30 lb).

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5. Install idler pinion, spacer, bearings and gears (11) and secure to a torque of 125 to 136 kg (90 to 100 lb).6. Using tooling (K) measure idler shaft end play and select a suitable shim pack to attain an end play of .076 to .152 mm (.003 to .006 in). This will give the proper amount of preload to the idler gear. After the measurement has been determined, perform step 5 and 6 again.

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7. Install assembled input shaft assembly (12) into front case.View Image

8. Install the input shaft bearing race into the rear case. Install a gasket and install the rear case (13) and secure with case bolts.

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9. Using tooling (K) measure input shaft end play and select a suitable shim pack to attain an end play of .025 to .076 mm (.001 to .003 in). This will give the proper amount of preload to the idler gear. After the measurement has been determined, perform step 9 again.10. Remove the rear case and insert the proper shim pack below the bearing cones, then remove the input shaft.

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11. Install assembled output shaft assembly (15). Install shifting forks (14) as shown. It may be necessary to slightly lift and fit the forks into the output shaft.

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12. Install countershaft assembly (16). To install countershaft (16) it will be necessary to raise the output shaft and forks slightly.

NOTE: After the installation of each of the gear assemblies into the transmission housing, each assembly should be turned to insure that it does not bind and that all gears mesh. View Image

13. Install input shaft (17).View Image

14. Install oil suction pipe (18) and secure with bolt (19). Tighten bolt (19) to a torque of 18 to 31 N·m (13 to 23 lb ft). Lock bolt (19) by bending the lock tabs on the corner of bracket holding tube (18).

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15. Engage second gear as shown, then position idler pinion, bearing and spacer (20) on the input shaft and shift fork.

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16. Install a new gasket between the two portions of the transmission case. Using tooling (B), install rear cover (22).

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17. Install reverse idler shim (23), spacers (24), bearing (25), gear (26), washer (27) and nut (28). Tighten nut to a torque of 122 to 136 N·m (90 to 100 lb ft).

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18. Install interlock detent balls (29). Return the transmission to the neutral position, then replace interlock detent plate (30). Tighten two bolts (31) in the interlock detent plate to a torque of 8 to 16 N·m (6 to 12 lb ft).

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19. Instal first and second shift lugs (33) and third and fourth shift lugs (34). Tighten Allen locking nut (32) on each of the lugs to a torque of 18 to 24 N·m (13 to 18 lb ft).

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20. Using a suitable depth gauge, measure the depth of the bearing race from the case. Add .12 mm (.005 in) to this figure. Select a suitable shim so that the shaft end play is .025 to .076 mm (.001 to .003 in).

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21. Repeat step 20 for output shaft (15).View Image

22. Install required shims (35) that are needed for steps 20 and 21.View Image

23. Install seal (36) in cover (37).View Image

24. Install a new gasket and install cover (37) onto the transmission case. Install eleven bolts (38) and tighten to a torque of 44 to 64 N·m (33 to 47 lb ft).

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25. Install O-ring (39) onto the lower seat (40) of stub lever (41). Install a new gasket between housing and upper seat (42). Install upper seat (42) and three bolts (43) to secure upper seat. Tighten three bolts (43) to a torque of 18 to 31 N·m (13 to 23 lb ft).

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26. Install detent ball (44), spring (45) and plug (46). Install new O-ring on plug (46). Tighten plug (46) to a torque of 40 to 54 N·m (30 to 40 lb ft).

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27. Install suction strainer O-ring (47), washer (49) and retaining plate (48). Secure with bolts (47) and tighten to a torque of 18 to 31 N·m (13 to 23 lb ft).

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28. Install a new gasket and 7M7260 Gasket Maker and install oil filter housing (51). Secure with two bolts (52) and tighten to a torque of 45 to 64 N·m (33 to 47 lb ft).

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29. Install a new gasket and 7M7260 Gasket Maker and install four wheel drive unit (53) and secure with four bolts (54). Tighten bolts (54) to a torque of 45 to 64 N·m (33 to 47 lb ft).

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30. Install a new gasket and 7M7260 Gasket Maker and install control valve unit (55) and secure with five bolts (56). Tighten bolts to a torque of 31 to 41 N·m (23 to 30 lb ft).

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31. Install oil drain plug (57) and tighten to a torque of 34 to 54 N·m (25 to 40 lb ft).View Image

32. Install output coupling (58). Use care not to destroy or damage the new oil seal.Assemble the transmission control valve as follows: NOTE: This control valve is used on the following models and serial numbers: 416B 8SG1-UP, 8ZK1-UP, 426B 5YJ1-UP, 6KL1-UP 428B 7EJ1-UP 436B 6MJ1-UP, 7FL1-UP 438B 3KK1-UP.NOTE: Prior to assembly, replace all old oil seals and gaskets with new. View Image

1. Install spring (18) and ball (19) into hole in selector assembly.2. Install new seal (17) on selector assembly (16) and install selector assembly while holding detent ball back.3. After selector assembly is in position and working properly, install snap ring (15).

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4. Install spool (13) as shown and seal and plug (14). Tighten plug (14) to a torque of 27 N·m (20 lb ft).

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5. Install three balls (12), seal and switch (11).View Image

6. Install ball (8), spring (9) and seal and plug (10).View Image

7. Install first spring (6), spool (5), second and third spring (6) and seal and plug (7). The second spring (6) sits inside the third spring (6).

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8. Install spring (4), spool (3), a new seal (2) and solenoid (1). Tighten solenoid to a torque of 34 to 54 N·m (25 to 40 lb ft).

Assemble the transmission four wheel drive transfer gear box as follows: NOTE: Prior to assembly, replace all oil seals, O-rings and gaskets. It is also important to soak the clutch pack plates in clean oil for three hours. View Image

1. Install O-ring seal (34) in cylinder (20).View Image

2. Soak piston seal ring (32) in warm water and install the seal as shown on piston (33). Install O-ring (31).

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3. Install piston (33) with seal (32) into tooling (J), and leave for 30 minutes. This will compress the seal for easy assembly.

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4. Install piston (33) into cylinder (20).View Image

5. Install clutch plates (25) into splined gear hub (22) starting with an internally splined friction disc and alternating with externally splined discs.

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6. Install thrust washer (26). Install clutch hub (24) into lower hub (22).

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7. Position spring pack (21) over the spring locations, then reposition cylinder (20) and piston and spring unit as shown.

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8. Position case (18) as shown.View Image

9. Install the gear assembly (19) into the case (18) as shown.View Image

10. Heat and install bearing (17) onto shaft.View Image

11. Install anti-rotation pin (35) into output shaft. Install the output shaft through case assembly (18).

NOTE: Make sure that the anti-rotation pin lines up with the slot in the cylinder. View Image

12. Install bearing (17) outer race and O-ring (16).View Image

13. Install seals (30) onto sleeve (15) as shown.View Image

14. Install sleeve (15) with the smaller chamfer upward.View Image

15. Install O-rings (14) and insure that they are correctly seated. Install control housing (13) and secure with four bolts (12). Tighten bolts (12) to a torque of 45 to 64 N·m (33 to 47 lb ft).

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16. Turn the unit over and install the sleeve and bearings (29).View Image

17. Install spacer (6) and shim (7).View Image

18. Heat bearing and install onto shaft. Install bearing race.NOTE: Check that the lower clutch plates do not become dislodged. View Image

19. Install spacer and washer. Install nut (8) and tighten to a torque of 112 to 144 N·m (90 to 120 lb ft).

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20. Install spacer, gasket and end cover (5) and secure with four bolts (4). Tighten to a torque of 45 to 64 N·m (33 to 47 lb ft).

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21. Turn four wheel drive assembly over and install a dial indicator, measure the end play of the drive assembly. Install the appropriate shims to allow end play of .02 to .07 mm (.001 to .003 in). Shimming procedure is covered in the next step.

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22. Turn drive assembly over and remove four bolts (4), cover (5) and spacer (6). Install the necessary shims (7). Install a new gasket and install cover, spacer and four bolts. Tighten bolts to a torque of 45 to 64 N·m (33 to 47 lb ft).

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23. Install output yoke (3), O-ring and washers (2). Secure with bolt and tighten to a torque of 68 to 88 N·m (50 to 65 lb ft). Bend lock tabs over bolt head to lock in position.

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24. Install spring (11) (not shown), and spool (10). Make sure that the large chamfer is facing upward. Install solenoid (9) and tighten to a torque of N·m (25 to 40 lb ft).

End By: a. install torque converterb. install transmission

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