Caterpillar Motor Grader Series 24 Technician ChecklistDifferential Removal and Installation{0372, 0374, 3258, 3258} Caterpillar

Caterpillar Motor Grader Series 24 Technician ChecklistDifferential Removal and Installation{0372, 0374, 3258, 3258}

Usage:

24H 7KK

Motor Grader:: 24H (S/N: 7KK1-UP); 24M (S/N: B9K1-UP; B931-UP)

Introduction

These checks are required for component removal and installation. Initial check after completion.

Note: Service literature procedures, specific to the model and serial number, must be used in this process. The checklist does not substitute procedures for the procedures given in the service literature.

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Table 1
Customer Name/ Location	Machine Unit Number	Machine Serial Number	Machine Service Meter Hours	Work Order Number
/

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Table 2
Differential Removed Sequence #	Differential Removed CID ⁽¹⁾ #	Differential Installed Sequence #	Differential Installed CID ⁽¹⁾ #	Differential Installed Source/Rebuilder ⁽²⁾

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^( 1 )	CID (Component Identification) is the number assigned to the component by the user/dealer.
^( 2 )	Suorce/Rebuilder is either NEW, REMAN, DLR (Dealer Rebuilt), or CUST (Customer Rebuilt).

Checklist

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Table 3

1.	Record Complaint:


2.	Pre-repair contamination control.
	A.	High-pressure wash the rear half of the motor grader to remove all dirt and debris.
	B.	Maintain a well-organized work area and plan to contain all fluid spills.
	C.	Keep components in original shipping package until installation, to keep clean.
	D.	Verify new parts cleanliness. Assure they are cleaned & capped/protected against dirt.

3.	Investigate differential history or failure cause, if appropriate.
	A.	Question the operator on application, operating conditions, and history. Review SOS history.
	B.	Review engine and transmission ECM's for detected faults and record in work order folder.
	C.	Take SOS Sample refer to: Contamination Control Guidelines, SEBF8482, "Obtaining Oil Sample for Analysis". Drain the engine and related power train oil reservoirs and visually check oil for water, coolant, or debris contaminants.
	D.	Inspect the magnetic drain plugs. Save any debris.
	E.	Remove/inspect system filters/screens and save any contamination evidence.

4.	If the differential failed generating metal/debris, remove, clean, and inspect and/or repair the final drives. Clean all vulnerable oil system components (reference the System Operations manual).

5.	High-pressure wash the machine area around the differential and transmission, before and after removal.

6.	Cover and cap all cleaned and reused components/lines until installed to prevent dirt entry. Cover all removed component cores with plastic sheets until shipping covers are available.

7.	Inspect drive shaft splines and U-joints for wear/damage. Reference Reuse And Salvage Guidelines, SEBF8126, "Universal Joints and Drive Shafts". Spline tooth wear limit is 0.2 mm (0.008 inch).

8.	Remove differential thrust pin and inspect for damage.

9.	Thoroughly clean the rear axle differential mounting surface. Thoroughly clean all axle housing cavities. Use lint-free towels to clean/check cleanliness. Immediately cover openings to keep clean.
	Supervisor sign-off required.

10.	Inspect transmission mounting areas and machine frame for wear, stripped threads, cracks, or deformation. Repair/replace and paint as needed.

11.	Remove and clean rear axle filtration system. Inspect and clean or replace system hoses and tubes. Refer to Tool Operating Manual, NEHS0643, "Using the 233-7191, 233-7192, 233-7193 and 265-4959 hose cleaning groups" and Contamination Control Guidelines, SEBF8485, "Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field Applications". Use new clamps (torque to spec), o-ring seals, and gaskets.

12.	Inspect the transmission filter bypass for correct operation (if transmission was removed).

13.	Inspect/replace the electrical connectors and harnesses for loose pins, brittleness, and fatigue.

14.	Install a standard 6-micron filter in the transmission system (if transmission is removed). Use as a clean-up filter for at least 8 hours operation time.				Record filter #:

15.	Clean/protect all mounting surfaces and exposed cavities of the transmission/differential.

16.	Transfer all covers/plugs to the removed component cores and pack into shipping containers to prevent damage and dirt entry. Tag with completed Cat dealer core tag.

17.	Install thrust pin - set preload.

	Clearance			Specification	Actual
	Thrust Pin Setting

18.	Use new bolts/u-joints to install the main drive shaft. Existing bolts cannot be reused:

	Bolt Torque			Specification	Actual
	Upper Shaft U-Joint
	Lower Shaft U-Joint

19.	Fill differential and transmission with oil meeting ISO --/16/13 cleanliness level.

22.	Before releasing machine, test differential and transmission oil cleanliness (if transmission was removed). Kidney-loop filtration may be required to achieve ISO cleanliness level of --/18/15 refer to Contamination Control Guidelines, SEBF8462, "Procedure for Filtering the Transmission Oil on 24H & 24M Motor Graders Equipped with Ecology Drain Valve". Attach particle count printouts.				Differential test #:
22.					Transmission test #:

23.	After 8 hours of operation without bypassing the filter, inspect the transmission clean-up filter and install a new standard filter. After 8 hours of operation, inspect the magnetic plug and check component and related systems for leaks. After one running shift and within 24 clock hours of installation, take a power train system oil sample and send to the Cat dealer, with this checklist, completed and signed.				Filter part number:




Technician Name:			Signature:			Date: