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


Transmission (Direct Drive) - Assemble
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1.1. Assembly Procedure
2.2. Transmission case
3.2. Direct Drive, Input Shaft
4.2. Direct Drive, Reverse Shaft
5.2. Direct Drive Shaft
6.2. Direct Drive, Rear Output Shaft
7.2. Direct Drive, Front Output Shaft
8.2. Final Assembly

Assembly 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 
137-8102  Spring Compressor 
1P-0510  Driver Gp 
Loctite High Flex Gasket Maker 
Loctite Retaining Compound 648(1) 
Loctite Retaining Compound 243(2) 
8T-5096  Dial Indicator Gp 
(1) Loctite 649 is acceptable.
(2) Loctite 242 is acceptable.

Note: The transmission will be assembled in major components. The major components will then be assembled.

Note: Apply a light film of clean transmission oil to all components before assembly.

Transmission case



    Illustration 1g03831934

  1. Install breather (168).


    Illustration 2g03831928


    Illustration 3g03832503

  2. Use Tooling (J) to install lip seal (162) into case (36). Dimension (X) is the depth to install lip seal (162) into case (36). Dimension (X) is 4.00 ± 0.25 mm (0.157 ± 0.010 inch).

    Note: Install the shims behind each bearing cup that was recorded on the disassembly procedure.

  3. Install bearing cup (159), bearing cup (160), bearing cup (161), bearing cup (163), and bearing cup (164) into case (36).


    Illustration 4g03831925

  4. Install temperature sensor (158). Tighten temperature sensor (158) to a torque of 20 ± 3 N·m (177 ± 27 lb in).


    Illustration 5g03831923

  5. Install O-ring seals (156) and (157) onto relief valve (150).


    Illustration 6g03831921

  6. Install O-ring seals (153), (154), and (155) onto relief valve (148).


    Illustration 7g03831920

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


    Illustration 8g03831917


    Illustration 9g03833490

  8. Install relief valve (148). Tighten relief valve (148) to a torque 46 N to 54 N·m (34 lb ft to 40 lb ft).

  9. Install relief valve (150). Tighten relief valve (150) to a torque 23 N to 30 N·m (204 lb in to 266 lb in).

  10. Use Tooling (J) to install lip seal (149) into the case. Dimension (Y) is the depth to install lip seal (149) into the case. Dimension (Y) is 3.00 ± 0.25 mm (0.118 ± 0.010 inch).

  11. Install pump (147), the O-ring seal, and bolts (146). Tighten bolts (146) to a torque of 18 N to 31 N·m (159 lb in to 274 lb in).

  12. Apply Tooling (K) to the case and install plate (145) and bolts (144).


    Illustration 10g03830896

  13. Apply Tooling (K) to the case and install torque converter housing (142) and bolts (143).


    Illustration 11g03830828

  14. Install bearing cup (136), bearing cup (137), bearing cup (138), bearing cup (139), bearing cup (140), and O-ring seals (141) into the case.

Direct Drive, Input Shaft



    Illustration 12g03833578

  1. Apply Tooling (L) to the input shaft and install gear (135). Raise temperature of bearing cone (134) and install bearing cone (134) on the input shaft. Install sealing ring (133) onto the input shaft.


    Illustration 13g03831169

  2. Install O-ring seals (131) and (132) onto piston (130).


    Illustration 14g03833579

  3. Install piston (130).


    Illustration 15g03830899

  4. Install sleeve (129).


    Illustration 16g03830898


    Illustration 17g03830895

    ------ 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. Install spring (128) and retainer (127). Use Tooling (H) and a suitable press to compress spring (128). Use Tooling (D) to install retaining ring (126).


    Illustration 18g03830897

  6. Install clutch pack (124) and thrust washer (125).


    Illustration 19g03830894

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


    Illustration 20g03830891

  8. Install thrust bearing (120) and needle bearing (121).


    Illustration 21g03830890

  9. Install gear (119) and thrust washer (118).


    Illustration 22g03830888

  10. Use Tooling (D) to install retaining ring (117). Install retaining ring (117).


    Illustration 23g03833580

  11. Raise temperature of bearing cone (116) and install on the input shaft.

  12. Install sealing rings (115).


    Illustration 24g03830884

  13. Install input shaft (114).

Direct Drive, Reverse Shaft



    Illustration 25g03830836

  1. Install O-ring seals (112) and (113).


    Illustration 26g03833581

  2. Install piston (111).


    Illustration 27g03830833

  3. Install sleeve (110).


    Illustration 28g03830831


    Illustration 29g03830830

    ------ 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.


  4. Install spring (109) and retainer (108). Use Tooling (H) and a suitable press to compress spring (109). Use Tooling (D) to install retaining ring (107).


    Illustration 30g03830829

  5. Install clutch pack (106).


    Illustration 31g03830827

  6. Install end plate (105) and retaining ring (104).


    Illustration 32g03830825

  7. Install thrust washer (103) and needle bearing (102) onto the reverse shaft.


    Illustration 33g03833582

  8. Install gear (99) and bearing (101) onto the reverse shaft.


    Illustration 34g03833583

  9. Install thrust washer (100) onto the reverse shaft.

  10. Raise temperature of bearing cone (98) and install bearing cone (98) onto the reverse shaft.

  11. Install ring seals (97) onto the reverse shaft.


    Illustration 35g03830819

  12. Install reverse shaft (96).

Direct Drive Shaft



    Illustration 36g03833585

  1. Raise temperature of bearing cone (95) and install bearing cone (95) onto the direct drive shaft.


    Illustration 37g03833586

  2. Raise temperature of bearing cone (94) and install bearing cone (94) onto the direct drive shaft.


    Illustration 38g03830710

  3. Install direct drive shaft (93).

Direct Drive, Rear Output Shaft



    Illustration 39g03833705

  1. Install bearing (92) and bearing spacer (91).


    Illustration 40g03833739

  2. Install gear (88) and sleeve (87) onto the rear output shaft.

  3. Raise temperature of sleeve (86). Install sleeve (86) and shims (83) onto the rear output shaft.


    Illustration 41g03833740

  4. Install bearing spacer (85) and bearing (84) onto the rear output shaft.


    Illustration 42g03833742

  5. Install synchronizer assembly (82) and shims (81) onto the rear output shaft.


    Illustration 43g03833743

  6. Install gear (90) onto the rear output shaft.

  7. Apply Tooling (L) to the splines of the rear output shaft and install gear (89).

  8. Raise temperature of cone bearing (80) and install cone bearing (80) onto the rear output shaft.


    Illustration 44g03829767

  9. Install needle bearings (79) and (78) onto the rear output shaft.


    Illustration 45g03829766

  10. Install gear (77) onto the rear output shaft.


    Illustration 46g03829811

  11. Install sleeve (76) onto the rear output shaft.


    Illustration 47g03829765

  12. Install synchronizer assembly (75) onto the rear output shaft.


    Illustration 48g03829764

  13. Use Tooling (D) to install lock ring (74).

  14. Install needle bearings (72) and (73) onto the rear output shaft.

  15. Install gear (71) onto the rear output shaft.


    Illustration 49g03833834

  16. Raise temperature of cone bearing (70) and install cone bearing (70) onto the rear output shaft.


    Illustration 50g03833835

  17. Apply Tooling (M) to the threads of screw (69). Install washer (68) and screw (69) onto the rear output shaft. Tighten screw (69) to a torque of 25 ± 2 N·m (221 ± 18 lb in).


    Illustration 51g03834035

  18. Install rear output shaft (65).


    Illustration 52g03829671


    Illustration 53g03834153

    ------ 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.


  19. Install spring (66) and ball (67) into the transmission case.

  20. While retaining spring (66) and ball (67) in the transmission case, install rod (63) and shift forks (64).


    Illustration 54g03829668


    Illustration 55g03829665

  21. Install ball (62) in the transmission case.

  22. Install rod (61) and screws (60). Tighten screws (60) to a torque of 22 ± 4 N·m (195 ± 35 lb in).


    Illustration 56g03829664


    Illustration 57g03829593

    ------ 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.


  23. Install ball (58), spring (59), plug (57), and the O-ring seal.

Direct Drive, Front Output Shaft



    Illustration 58g03833903

  1. Raise temperature of bearing cone (56) and install bearing cone (56) onto the front output shaft.


    Illustration 59g03833906

  2. Install seal ring (55) and piston (54).


    Illustration 60g03829483


    Illustration 61g03829482

    ------ 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.


  3. Install retainer (53) and spring assembly (52) into the front output shaft.

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


    Illustration 62g03829481


    Illustration 63g03829480

  5. Install friction clutches (50) and friction disks (49).


    Illustration 64g03829479

  6. Install end plate (48).


    Illustration 65g03829478

  7. Install retaining ring (47).


    Illustration 66g03833914

  8. Install thrust washer (46), needle bearing (45), roller bearing (44), spacer (43), and roller bearing (42) onto the front output shaft.


    Illustration 67g03833915

  9. Install gear (41) and needle bearing (40) onto the front output shaft.


    Illustration 68g03833945

  10. Raise the temperature of bearing cone (38). Install thrust washer (39) and bearing cone (38) onto the front output shaft.


    Illustration 69g03828880

  11. Install front output shaft (37).

Final Assembly



    Illustration 70g03828879


    Illustration 71g03834157

    Note: Clean the mating surfaces of the transmission cases. Apply Tooling (K) to the mating surface of the cases.

  1. Attach Tooling (A) and Tooling (B) to case (36). Attach a suitable lifting device to Tooling (A) and Tooling (B). The weight of case (36) is approximately 45 kg (100 lb). Install case (36) and bolts (35).


    Illustration 72g03834183


    Illustration 73g03834184


    Illustration 74g03834185

  2. Remove plugs (169), (170), and (171) from the transmission.


    Illustration 75g03834187


    Illustration 76g03834188


    Illustration 77g03834189

  3. Seat the shafts by rotating the shafts several times. Install Tooling (N), as shown. Zero Tooling (N). Pry up on the shaft and record the reading on Tooling (N). The reading must be 0.0127 mm to 0.1127 mm (0.00050 inch to 0.00444 inch). Add or remove shims in Step 3 in the Case Assembly Procedure to obtain the correct reading.

  4. Reinstall plugs (169), (170), and (171) from the transmission.


    Illustration 78g03834197


    Illustration 79g03834198

  5. Install bolt (11) and the washer into the output shaft. Pry up on the bolt and washer. Repeat Step 3 for the input shaft and the output shaft (rear). Use the same tolerance for all the shafts.


    Illustration 80g03831932

  6. Install O-ring seals (167) onto solenoid valves (165).


    Illustration 81g03831929

  7. Install solenoid valves (165) and bolts (166). Tighten bolts (166) to a torque of 3 N to 4 N·m (27 lb in to 35 lb in).


    Illustration 82g03834203

  8. Install O-ring seals (34) into solenoid valve (12).


    Illustration 83g03828852


    Illustration 84g03834208

    ------ 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. Install spool (33), washer (32), push rod (31), and spring (30) into solenoid valve (12).

  10. Install O-ring seal (29) on tube assembly (28).

  11. Install tube assembly (28) on solenoid valve (12). Tighten tube assembly (28) to a torque of 30 ± 5 N·m (266 ± 44 lb in).


    Illustration 85g03828850


    Illustration 86g03834210

  12. Install O-ring seal (27), coil assembly (25), O-ring seal (26), and self-locking nut (24) on solenoid valve (12). Tighten self-locking nut (24) to a torque of 3 ± 0.5 N·m (27 ± 4.43 lb in).


    Illustration 87g03828848


    Illustration 88g03834282

    ------ 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. Install poppet (23) and spring (22) in solenoid valve (12).

  14. Install O-ring seal (21) on plug (20). Install plug (20) on solenoid valve (12). Tighten plug (20) to a torque of 15 ± 5 N·m (133 ± 44 lb in).


    Illustration 89g03828846


    Illustration 90g03834283

    ------ 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.


  15. Install piston (19), spring (18), carrier (17), and spring (16) in solenoid valve (12).

  16. Install O-ring seal (15) on head (14). Install head (14) on solenoid valve (12). Tighten head (14) to a torque of 30 ± 5 N·m (266 ± 44 lb in).


    Illustration 91g03828844

  17. Install solenoid valve (12) and bolts (13) onto transmission (2). Tighten bolts (13) to a torque of 8 ± 1 N·m (71 ± 9 lb in).


    Illustration 92g03828843

  18. Install yoke (9), the washer, and bolt (11) onto transmission (2). Tighten bolt (11) to a torque of 68 N to 88 N·m (50 lb ft to 65 lb ft).

  19. Install support assemblies (8) and bolts (10) onto transmission (2).

  20. Install gear shift (6) and bolts (7) onto transmission (2).

  21. Install shaft (5) into transmission (2).


    Illustration 93g03827943

  22. Install yoke (3), the washer, and bolt (4) onto transmission (2). Tighten bolt (4) to a torque of 68 N to 88 N·m (50 lb ft to 65 lb ft).

  23. Use two people to install torque converter (1). The weight of torque converter (1) is approximately 23 kg (51 lb). Install torque converter (1) onto transmission (2).

End By:

  1. Install the transmission.

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