PRODUCT IMPROVEMENT PROGRAM FOR REWORKING CERTAIN 8E-9035, 246-2647, 315-6272, 0R-4005, 10R-8424 AND 20R-3956 NEW OR EXCHANGE TRANSMISSIONS IN DEALER OR CUSTOMER INVENTORY Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING CERTAIN 8E-9035, 246-2647, 315-6272, 0R-4005, 10R-8424 AND 20R-3956 NEW OR EXCHANGE TRANSMISSIONS IN DEALER OR CUSTOMER INVENTORY

Usage:

TEBE3737-01

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04Dec2015

(Revised 21Dec2015)

U-649

A-470

D-572

O-562

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Parts stock action only	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING CERTAIN 8E-9035, 246-2647, 315-6272, 0R-4005, 10R-8424 AND 20R-3956 NEW OR EXCHANGE TRANSMISSIONS IN DEALER OR CUSTOMER INVENTORY
7750		PI70600

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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:	When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 04Dec2015 Service Letter. Changes have been made to the Title, Action Required, Service Claim Allowances, and Rework Procedure.

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TERMINATION DATE

31Mar2016

PROBLEM

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Improved gears are now available for planetary gear train two in 8E-9035, 246-2647, 315-6272, 0R-4005, 10R-8424 and 20R-3956 Transmissions. Continued use of the former gears may result in reduced service life of the transmission.

ACTION REQUIRED

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Disassemble the transmission, remove one 3T-9413 Gear-Sun, three 3T-9418 Gear-Planet, and one 9W-9815 Gear As-Ring in train 2, install one 4568268/">456-8268 Gear-Sun, three 4568270/">456-8270 Gear-Planet, and one 4605438/">460-5438 Gear As-Ring in train 2. Reassemble the transmission using a new 7G-6373 Gasket for the controls cover plate. Refer to Disassembly and Assembly Manual RENR8428 (777D), RENR8304 (777F) or KENR9931 (777G) as needed.

For 777G transmissions, refer to the attached Rework Procedure for installation of the new speed sensor and harness.

NOTE: While disassembled, verify that the transmission has the 443-0663 Disc-Friction and 391-4047 Plate-Clutch installed in clutch 3.

NOTE: The new gears are already installed in transmissions as follows:
8E-9035: 1FX07986-Up
246-2647: LSP04282-Up
315-6272: GGG01566-Up
0R-4005: 10249235-Up, AK40050190-Up
10R-8424: 10249235-Up
20R-3956: 10249235-Up
These transmissions do not need to be reworked.

Note: This Service Letter covers reworks to new or rebuilt transmissions in either dealer or customer inventory.

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SERVICE CLAIM ALLOWANCES

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Submit one claim for all transmission reworked in dealer stock. A total of 24 hours labor plus 1 - 7G6373 Gasket, 1 - 4568268 Gear-Sun, 3 - 4568270 Gear-Planet, and 1 - 4605438 Gear As-Ring will be allowed for each transmission reworked. For 777G Transmissions 1 - 484-9920 Harness, 1 - 191-8303 Sensor, 2 - 3S-2093 Strap-Cable, and 1 - 117-1385 O-ring will also be allowed.

PARTS DISPOSITION

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Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.

Rework Procedure

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NOTE: This procedure only applies to 777G transmissions.

Note: This procedure is done after the transmission planetary group is installed in the case.

Connect the 484-9920 Harness to the 191-8303 Sensor. The harness should be looped and tied back to the sensor body using one 3S-2093 Strap-Cable to relieve tension on the wires into the connector body. Install the 117-1385 O-ring on the sensor.

Image1.1.1

Install the sensor into the transmission planetary. Route the harness up to the ladder clip attached to the planetary case. Loop the harness around the ladder clip and secure with a 3S-2093 Strap-Cable.