415F2 Industrial Loader Power Train Transmission (Direct Drive) - Disassemble Caterpillar


Transmission (Direct Drive) - Disassemble
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1.1. Disassembly Procedure
2.2. Direct Drive, Front Output Shaft
3.2. Direct Drive, Rear Output Shaft
4.2. Direct Drive Shaft
5.2. Direct Drive, Reverse Shaft
6.2. Direct Drive, Input Shaft
7.2. Transmission Case

Disassembly Procedure

Table 1
Required Tools 
Tool  Part Number  Part Description  Qty 
395-1590  Lifting Eye Assembly 
422-5471  Lifting Eye Assembly 
4C-3652  Spring Compressor 
1P-1859  Retaining Ring Pliers 
8H-0663  Bearing Puller Gp 
8B-7551  Bearing Puller Gp 
1U-6400  Three Jaw Puller 
137-8102  Spring Compressor 

Start By:

  1. Remove the transmission.


    Illustration 1g03827943

  1. Use two people to remove torque converter (1). The weight of torque converter (1) is approximately 23 kg (51 lb). Remove torque converter (1) from transmission (2).

  2. Remove bolt (4), the washer, and yoke (3) from transmission (2).


    Illustration 2g03828843

  3. Remove shaft (5) from transmission (2).

  4. Remove bolts (7) and gear shift (6) from transmission (2).

  5. Remove bolts (10) and support assemblies (8) from transmission (2).

  6. Remove bolt (11), the washer, and yoke (9) from transmission (2).


    Illustration 3g03828844

  7. Remove bolts (13) and solenoid valve (12) from transmission (2).


    Illustration 4g03828845


    Illustration 5g03828846

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  8. Remove head (14) from solenoid valve (12). Remove O-ring seal (15) from head (14).

  9. Remove spring (16), carrier (17), spring (18), and piston (19) from solenoid valve (12).


    Illustration 6g03828847


    Illustration 7g03828848

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  10. Remove plug (20) from solenoid valve (12). Remove O-ring seal (21) from plug (20).

  11. Remove spring (22) and poppet (23) from solenoid valve (12).


    Illustration 8g03828849


    Illustration 9g03828850

  12. Remove self-locking nut (24), O-ring seal (26) coil assembly (25), and O-ring seal (27) from solenoid valve (12).


    Illustration 10g03828851


    Illustration 11g03828852

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  13. Remove tube assembly (28) from solenoid valve (12). Remove O-ring seal (29) from tube assembly (28).

  14. Remove spring (30), push rod (31), washer (32), and spool (33) from solenoid valve (12).


    Illustration 12g03828876

  15. Remove O-ring seals (34) from solenoid valve (12).

  16. Repeat Step 8 through Step 14 for the opposite side of solenoid valve (12).


    Illustration 13g03828878

  17. Attach Tooling (A) and a suitable lifting device to transmission (2). The weight of transmission (2) is approximately 255 kg (562 lb). Place transmission (2) on a suitable work bench. Secure transmission (2) to the suitable work bench.

  18. Remove bolts (35) that secure the case.


    Illustration 14g03828879

  19. Attach Tooling (A) and Tooling (B) to case (36). The weight of case (36) is approximately 45 kg (100 lb). Remove case (36) from the transmission.

Direct Drive, Front Output Shaft



    Illustration 15g03828880

  1. Remove front output shaft (37).


    Illustration 16g03829476


    Illustration 17g03829477

  2. Use suitable press to remove bearing cone (38).

  3. Remove bearing cone (38), thrust washer (39), needle bearing (40), and gear (41) from the shaft.

  4. Remove roller bearing (42), spacer (43), roller bearing (44), needle bearing (45), and thrust washer (46) from the shaft.


    Illustration 18g03829478

  5. Remove retaining ring (47).


    Illustration 19g03829479

  6. Remove plate (48).


    Illustration 20g03829480


    Illustration 21g03829481

  7. Remove friction disks (49) and friction clutches (50).


    Illustration 22g03829482

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  8. Use a suitable press and Tooling (C) to compress spring assembly (52). Use Tooling (D) to remove retaining ring (51).


    Illustration 23g03829483

  9. Remove spring assembly (52) and retainer (53).


    Illustration 24g03829484

  10. Release piston (54) by applying 207 kPa (30 psi) of air pressure into the lube passage as indicated.

  11. Remove seal ring (55).


    Illustration 25g03829485

  12. Use Tooling (E) and a suitable press to remove bearing cone (56). Remove bearing cone (56).

Direct Drive, Rear Output Shaft



    Illustration 26g03829593


    Illustration 27g03829664

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  1. Remove plug (57), spring (59), and ball (58).


    Illustration 28g03829665


    Illustration 29g03829668

  2. Remove screws (60) from the shift forks. Remove rod (61) and ball (62).


    Illustration 30g03829669

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


    Note: Reinstalling plug (57) keeps the spring and the ball from being propelled from the transmission case.

  3. Reinstall plug (57) into the transmission case.

  4. Remove rod (63) and shift forks (64).


    Illustration 31g03829670


    Illustration 32g03829671

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  5. Remove plug (57), ball (67), and spring (66).

  6. Remove rear output shaft (65).


    Illustration 33g03829672


    Illustration 34g03829763

  7. Remove screw (69) and washer (68).

  8. Use Tooling (F) and a suitable press to remove bearing cone (70) and gear (71).


    Illustration 35g03829764

  9. Remove needle bearings (72) and (73).

  10. Use Tooling (D) to remove lock ring (74).


    Illustration 36g03829765

  11. Remove synchronizer assembly (75).


    Illustration 37g03829811

  12. Remove sleeve (76).


    Illustration 38g03829766

  13. Remove gear (77).


    Illustration 39g03829767

  14. Remove needle bearings (78) and (79).


    Illustration 40g03829768


    Illustration 41g03829812

  15. Use a suitable press to remove bearing cone (80) from the shaft. Remove bearing cone (80), gear (89), gear (90).

  16. Remove shims (81), synchronizer assembly (82), and shims (83).

  17. Remove bearing (84), bearing spacer (85), and sleeve (86).

  18. Remove sleeve (87), gear (88), bearing spacer (91), and bearing (92).

Direct Drive Shaft



    Illustration 42g03830710

  1. Remove direct drive shaft (93).


    Illustration 43g03830711

  2. Use Tooling (F) and a suitable press to remove bearing cone (94). Remove bearing cone (94).


    Illustration 44g03830712

  3. Use Tooling (E) and a suitable press to remove bearing cone (95). Remove bearing cone (95).

Direct Drive, Reverse Shaft



    Illustration 45g03830819

  1. Remove reverse shaft (96).


    Illustration 46g03830821

  2. Remove ring seals (97).


    Illustration 47g03830822


    Illustration 48g03830824

  3. Use Tooling (G) to remove bearing cone (98). Remove bearing cone (98), thrust washer (100), bearing (101), and gear (99).


    Illustration 49g03830825

  4. Remove needle bearing (102) and thrust washer (103).


    Illustration 50g03830827

  5. Remove retaining ring (104) and end plate (105).


    Illustration 51g03830829

  6. Remove clutch pack (106).


    Illustration 52g03830830


    Illustration 53g03830831

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  7. Use a suitable press and Tooling (H) to compress spring (109). Use Tooling (D) to remove retaining ring (107). Compress spring (109) and remove retaining ring (107).

  8. Remove retainer (108) and spring (109).


    Illustration 54g03830833

  9. Remove sleeve (110).


    Illustration 55g03830835

  10. Release piston (111) by applying 207 kPa (30 psi) of air pressure into the lube passage as indicated.


    Illustration 56g03830836

  11. Remove O-ring seals (112) and (113).

Direct Drive, Input Shaft



    Illustration 57g03830884

  1. Remove input shaft (114).


    Illustration 58g03830885

  2. Remove sealing rings (115).


    Illustration 59g03830887

  3. Use a suitable press and Tooling (F) to remove bearing cone (116).


    Illustration 60g03830888

  4. Use Tooling (G) to remove retaining ring (117).


    Illustration 61g03830890

  5. Remove thrust washer (118) and gear (119).


    Illustration 62g03830891

  6. Remove needle bearing (121) and thrust bearing (120).


    Illustration 63g03830894

  7. Remove retaining ring (122) and end plate (123).


    Illustration 64g03830897

  8. Remove thrust washer (125) and clutch pack (124).


    Illustration 65g03830895


    Illustration 66g03830898

    ------ WARNING! ------

    Personal injury can result from being struck by parts propelled by a released spring force.

    Make sure to wear all necessary protective equipment.

    Follow the recommended procedure and use all recommended tooling to release the spring force.


  9. Use Tooling (H) and a suitable press to compress spring (128). Use Tooling (D) to remove retaining ring (126). Compress spring (128) and remove retaining ring (126).

  10. Remove retainer (127) and spring (128).


    Illustration 67g03830899

  11. Remove sleeve (129).


    Illustration 68g03830901

  12. Release piston (130) by applying 207 kPa (30 psi) of air pressure into the lube passage as indicated.


    Illustration 69g03831169

  13. Remove O-ring seals (131) and (132) from piston (130).


    Illustration 70g03830900

  14. Remove sealing ring (133).

  15. Use a suitable press and Tooling (F) to remove bearing cone (134) from the input shaft. Remove bearing cone (134) and gear (135).

Transmission Case



    Illustration 71g03830828

  1. Remove bearing cup (136), bearing cup (137), bearing cup (138), bearing cup (139), bearing cup (140), and O-ring seals (141) from the case.


    Illustration 72g03830896

  2. Remove bolts (143) and torque converter housing (142).


    Illustration 73g03831917

  3. Remove bolts (144) and plate (145).

  4. Remove bolts (146) and pump (147).

  5. Remove lip seal (149).

  6. Remove relief valves (148) and (150).


    Illustration 74g03831920

  7. Remove bolts (151) and strainer (152).


    Illustration 75g03831921

  8. Remove O-ring seals (153), (154), and (155) from relief valve (148).


    Illustration 76g03831923

  9. Remove O-ring seals (156) and (157) from relief valve (150).


    Illustration 77g03831925

  10. Remove temperature sensor (158).


    Illustration 78g03831928

    Note: Note the number of shims when you remove each of the bearing cups.

  11. Remove bearing cup (159), bearing cup (160), bearing cup (161), and bearing cup (164) from case (36). Remove bearing cup (163) and lip seal (162) from case (36).


    Illustration 79g03831929

  12. Remove bolts (166) and solenoid valves (165).


    Illustration 80g03831932

  13. Remove O-ring seals (167) from solenoid valves (165).


    Illustration 81g03831934

  14. Remove breather (168).

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