2004/05/03 Caterpillar

Articulated Truck:

D250D (S/N: 6NG1-UP)

D250E (S/N: 5TN1-UP)

D300D (S/N: 5MG1-UP)

D300E (S/N: 7FN1-UP)

D350D (S/N: 9RF1-UP)

D350E (S/N: 9LR1-UP)

D400D (S/N: 8TF1-UP)

D400E (S/N: 2YR1-UP)

Service Magazine SEPD0680, 21 April 2003, "New Midshaft Bearing Assemblies Now Used to Increase Service Life". Disregard this article. See the article that follows.

Reference: Disassembly and Assembly, SENR8653, "D250E and D300E Articulated Truck Power Train", "Drive Shaft, (Transfer Gear to Mid Bearing)" This module is found in Service Manual, SENR8650.

Reference: Disassembly and Assembly, SENR8653, "D250E and D300E Articulated Truck Power Train", "Drive Shaft, (Mid Bearing to Rear Axle)" This module is found in Service Manual, SENR8650.

Reference: Disassembly and Assembly, SENR8692, "350E and D400E Articulated Truck Power Train", "Drive Shaft, (Transfer Gear to Mid Bearing)" This module is found in Service Manual, SENR8690.

Reference: Disassembly and Assembly, SENR8692, "350E and D400E Articulated Truck Power Train", "Drive Shaft, (Mid Bearing to Rear Axle)" This module is found in Service Manual, SENR8690.

Description of Change: New rear drive shaft groups with new midbearing drive shafts increase service life. The new midbearing drive shafts use an additional universal joint instead of spherical housings.

Adaptable To: The new 135-1696 Rear Drive Shaft Group replaces the former 126-7351 Rear Drive Shaft Group. The new 135-1694 Rear Drive Shaft Group replaces the former 129-9115 Rear Drive Shaft Group. The new 135-1693 Rear Drive Shaft Group replaces the former 7U-7504 Rear Drive Shaft Group.

Illustration 1	g01070906
Typical Example of the Design of the Former Midbearing Drive Shaft with Spherical Bearing

Illustration 2	g01070905
Typical Example of the Design of the New Midbearing Drive Shaft

The designs of the former midbearing drive shaft and the current midbearing drive shaft are shown in Illustrations 1and 2.

The new 135-1696 Rear Drive Shaft Group and the new 135-1694 Rear Drive Shaft Group include a new 131-8403 Rear Drive Shaft Group (Midbearing) that replaces the former 126-7352 Midbearing Drive Shaft Group. The new 135-1696 Rear Drive Shaft Group and the new 135-1694 Rear Drive Shaft Group require four additional 0S-0484 Bolts for installation and a shorter drive shaft in order to connect the output yoke for the six wheel drive splitter box to the input yoke for the new midbearing drive shaft.

The new 135-1693 Rear Drive Shaft Group includes a new 131-8404 Midbearing Drive Shaft Group that replaces the former 2U-8046 Midbearing Drive Shaft Group. The new 135-1693 Rear Drive Shaft Group requires four additional 0S-1579 Bolts for installation and a shorter drive shaft in order to connect the output yoke for the six wheel drive splitter box to the input yoke for the new midbearing drive shaft.

The new 135-1696 Rear Drive Shaft Group is effective with D400E S/N:2YR698-UP. The new 135-1694 Rear Drive Shaft Group is effective with D350E S/N:9LR421-UP. The new 135-1693 Rear Drive Shaft Group is effective with D250E S/N:5TN1344-UP and D300E S/N:7FN685-UP.

The new rear drive shaft groups are adaptable to earlier machines by using the following procedure. Refer to Table 1 for the needed parts.

Note: The new drive shaft from the transfer gear group needs to be installed in the rear chassis prior to installation of the new bearing assembly.

Note: The new bearing assembly must be installed in the chassis without the front yoke. The front yoke is larger than the opening in the chassis.

Note: Some "E-Series" trucks were modified to the larger hole diameter prior to shipment from the factory. Check the hole before starting any work.

Table 1

Needed Parts
Item	Qty	Part Number	Description	Models
1	1	131-8398	Housing	All Models
2	1	131-8400	Housing	All Models
3	2	131-1010	Ball Bearings	All Models
4	1	1F-2771	Ball Bearing	All Models
5	2	5P-1086	Lip Seals	All Models
6	4	7X-0356	Bolts	D350D, D350E D400D, D400E
6	4	7X-0354	Bolts	D250D, D250E D300D, D300E
7	4	8T-4122	Hard Washers	All Models
8	2	7X-0488	Nuts	All Models
9	1	131-8401	Drive Shaft	All Models
10	2	142-1280	Drive Yokes	D350D, D350E D400D, D400E
10	2	143-7284	Drive Yokes	D250D, D250E D300D, D300E
11	2	142-1281	Retainers	All Models
12	2	7X-0350	Bolts	All Models
13	2	4U-4060	Dirt Guards	All Models
14	2	2U-1574	O-Ring Seals	All Models
15	1	142-1282	Shim Pack	All Models
16	4	4L-9337	Bolts	All Models
17	4	8T-4896	Hard Washers	All Models
18	2	142-2670	Seal Rings	All Models
	1	177-1637	Universal Joint Group	D350D, D350E D400D, D400E
	1	125-9177	Universal Joint Group	D250E, D300E
	1	2U-8558	Universal Joint Group	D250D, D300D
	4	0S-0484	Bolts	D350D, D350E D400D, D400E
	4	0S-1579	Bolts	D250D, D250E D300D, D300E
	1	2S-3230	Bearing Lubricant	All Models
	1	5P-0960	Molybdenum Grease	All Models

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Personal injury can result from driveline torque windup under load. Unequal wheel speed can result in driveline torque windup which can cause driveline components to be under load during disassembly. Relieve the driveline torque windup before disassembly.

1. Reference the disassembly and assembly modules. Remove the drive shafts. Remove the drive shafts.

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Illustration 3	g00960231
(A) Location of the hole for the midbearing drive shaft

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Illustration 4	g00956751
(A) Original diameter (B) New diameter (C) Hole (D) Radius (E) Radius

2. Remove the midbearing drive shaft. Enlarge the hole (A) in order to accept the new drive shaft. The diameter of the new opening (B) should be 171.5 mm (6.75 inch). Configure the hole to the dimensions that are shown in Illustration 4 .

   Original diameter ... A

   New diameter (B) ... 171.5 mm (6.75 inch)

   Diameter of hole (C) with the existing center ... 18.0 mm (0.70 inch)

   Radius (D) ... 15.0 mm (0.60 inch)

   Radius (E) ... 25.0 mm (1.0 inch)

Illustration 5	g00956766

Illustration 6	g00956776

Note: In order to assemble the midbearing drive shaft, use a 25 mm (1.0 inch) outside micrometer and a depth micrometer with a 25 mm (1.0 inch) travel. In order to make the adjustment to the drive shaft support bearing, use a 25 mm (1.0 inch) outside micrometer and a depth micrometer with a 25 mm (1.0 inch) travel. Use the following steps to shim the bearing.

3. Measure the thickness of the 131-8400 Housing with the outside micrometer near hole (19) in 5.

4. Install the 131-1010 Ball Bearing (3) with the word "Thrust" toward each other on the inside diameter of the bearing races. Install the 131-8400 Housing (1) without shims on the four 4L-9337 Bolts (16) and the four 8T-4896 Hard Washers (17) in 5. Torque the four bolts to 12 ± 2 N·m (105.0 ± 18.0 lb in).

5. With the depth micrometer, measure the depth through hole (19) in the 131-8400 Housing. Note the measurement. Subtract the thickness of the housing from the depth measurement. This number is the required thickness of the shim pack.

6. With the outside micrometer, measure the 142-1282 Shim Pack. The measurement must be within ± 0.025 mm (± 0.0010 inch) of the required thickness.

7. Remove the four bolts and the housing. Assemble the midbearing drive shaft with the needed shims. Install the four bolts. Torque for the four bolts 47 ± 9 N·m (35.0 ± 7.0 lb ft)

Note: Pack 30 to 50 percent of the seal, the bearings, and the housing with 2S-3230 Bearing Lubricant. Before assembly, apply the bearing lubricant to the lips of the seal.

Note: After assembly, the ears of the drive yokes must align with each other.

Note: Before assembly, apply 5P-0960 Molybdenum Grease to all spline.

8. Install the bearing assembly to the frame. In order to install the drive shafts, follow the procedures in the disassembly and assembly module for your machine.

Note: The torque for the two 7X-0350 Bolts is 270 ± 40 N·m (200.0 ± 30.0 lb ft).