PRODUCT SUPPORT PROGRAM FOR REPLACING 8W-9149 DIFFERENTIAL BEVEL GEARS AND 3D-8513 THRUST WASHERS ON CERTAIN 777G OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING 8W-9149 DIFFERENTIAL BEVEL GEARS AND 3D-8513 THRUST WASHERS ON CERTAIN 777G OFF-HIGHWAY TRUCKS

Usage:

TEBE3617-01

Show/hide table

15Dec2015

(Revised 25Aug2016)

K02C
K030
K031
K040
K042
K113
K230
K311
K314
K350
K430
K450
K590
K632
K645
K646
K680
K690
Q630
Q632

Show/hide table

Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING 8W-9149 DIFFERENTIAL BEVEL GEARS AND 3D-8513 THRUST WASHERS ON CERTAIN 777G OFF-HIGHWAY TRUCKS
7755 3258		PS44941

Show/hide table

NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS44941" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

NOTE:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

Show/hide table


NOTE:	This Revised Service Letter replaces the 15Dec2015 Service Letter. Changes have been made to the Affected Product and Action Required.

Show/hide table

TERMINATION DATE

31Dec2017

PROBLEM

Show/hide table

The existing 3D-8513 Thrust Washers can wear on certain 777G Off-Highway Trucks. The 8W-9149 Differential Bevel Gear contact surface with the thrust washer is too rough and can cause premature wear on the thrust washer. If the existing thrust washers wear they can result in damage to, but not limited to the bevel and pinion gears.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
777G	TNM00112, 114, 118-120, 122, 124, 135, 137, 139, 141, 159-161, 166, 168, 170, 172, 174, 176-179, 195, 197, 199, 201, 203, 234-236, 238, 241, 243, 255, 257, 259, 261, 263, 275, 282, 288, 291, 300-302, 311-313, 340-341, 346, 349, 351, 353, 355, 360, 390-392, 419, 421, 423, 557, 563, 583, 589-600, 604-606, 608-611, 620, 639-640, 659-668, 670-674, 735-740, 758, 764-767, 779-787, 789-790, 800-804, 815-817, 823-824, 827-828, 833-848, 857, 860-861
777G OEM	M6J00119-00120 T4Y00138-00139, 149, 156-157, 166-169, 176, 190-191, 197

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
1	2D6506	SEAL-O-RING
1	2D8364	SEAL-O-RING
1	2H3932	SEAL-O RING
4	3D6509	DOWEL
2	3D8513	WASHER-THRUST
1	7S8554	SEAL-O RING
2	4761192	GEAR-DIFF BEVEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

Show/hide table

Refer to the Service Manual if/as necessary.
Replace the existing 8W-9149 Differential Bevel Gears with 476-1192 Differential Bevel Gears.
Reference KENR9931, "777G Off-Highway Truck Power Train Disassembly and Assembly," as needed.

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-12000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
12001-16000 hrs, 37-48 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
16001-24000 hrs, 49-60 mo	33.0%	0.0%	0.0%	0.0%	50.0%	100.0%

Show/hide table

NOTE: This is a 36.0-hour job
This is a 36 hour job including time required to remove and install both axle shafts, remove and install the differential and bevel gear, and disassemble and assembly the differential and bevel gear. The time required to set the bashlash adjustment and bearing preload is also included.

Show/hide table