PRODUCT SUPPORT PROGRAM FOR REPLACING THE CLUTCH 3 DISCS AND PLATES AND 3T-9413 SUN GEAR, 3T-9418 PLANET GEARS AND 9W-9815 RING GEAR AS ON CERTAIN 777D, 777F AND 777G OFF-HIGHWAY TRUCKS AT PLANNED COMPONENT REBUILD (PCR) Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE CLUTCH 3 DISCS AND PLATES AND 3T-9413 SUN GEAR, 3T-9418 PLANET GEARS AND 9W-9815 RING GEAR AS ON CERTAIN 777D, 777F AND 777G OFF-HIGHWAY TRUCKS AT PLANNED COMPONENT REBUILD (PCR)

Usage:

TEBE3738-02

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25Jan2016

(Revised 05Jun2017)

U-38

A-31

D-38

O-33

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Before/After	PRODUCT SUPPORT PROGRAM FOR REPLACING THE CLUTCH 3 DISCS AND PLATES AND 3T-9413 SUN GEAR, 3T-9418 PLANET GEARS AND 9W-9815 RING GEAR AS ON CERTAIN 777D, 777F AND 777G OFF-HIGHWAY TRUCKS AT PLANNED COMPONENT REBUILD (PCR)
3160		PS44968

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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:

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 "PS44968" 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.

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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 25Jan2016 (Revised 29Feb2016) Service Letter. Changes have been made to the Action Required and Service Claim Allowances.

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TERMINATION DATE

31Jan2020

PROBLEM

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The existing gears used in train two of the transmission planetary group should be replaced at PCR on certain 777D, 777F and 777G Off-Highway Trucks. Reuse of these gears may result in fracture of the friction discs in clutch 3. New friction discs and clutch plates should also be installed.

AFFECTED PRODUCT

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Model	Identification Number
777D	FKR00022, 200-2409
777F	JRP00277-03340
777F OEM	JXP00100-00258 WTK00105-00117
777G	GT700142-00147, 150-156 RDR00102-00258, 261-336, 341-345, 347 TNM00101-00757, 759-828, 830-848, 851, 857
777G OEM	M6J00100-00125 T4Y00100-00195, 197-206 T5A00100-00122

PARTS NEEDED

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Qty	Part Number	Description
2	3914047	PLATE-CLUTCH
3	4430663	DISC-FRICTION
1	4568268	GEAR-SUN
3	4568270	GEAR-PLANET
1	4605438	GEAR AS-RING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 27% 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

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At time of transmission overhaul, identify the part numbers of the friction discs and clutch plates used in clutch 3 and the gears used in planetary gear train 2.

Install new clutch discs and plates if the transmission does not contain the 443-0663 Disc-Friction and the 391-4047 Plates-Clutch. Reference Service Magazine Article SEPD1866 "An Improved Transmission Planetary Group Is Now Used on Certain 777 Off-Highway Trucks".

If the transmission contains the 3T-9413 Gear-Sun, 3T-9418 Gear-Planet and 9W-9815 Gear As-Ring, these parts should be removed and replaced with the 456-8268 Gear-Sun, 456-8270 Gear-Planet and 460-5438 Gear As-Ring. Reference Service Magazine Article M0067196 "New Gears Available for 777 Transmissions".

NOTE: This program does not apply to any transmission that is equipped with the new 456-8268 Gear-Sun, 456-8270 Gear-Planet, and 460-5438 Gear As-Ring.

NOTE: This program can not be combined with any other program to repair/rebuild the transmission.

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SERVICE CLAIM ALLOWANCES

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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%
0-10000 hrs, 0-60 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%
10001-15000 hrs, 61-90 mo	67.0%	0.0%	0.0%	0.0%	25.0%	100.0%
15001-20000 hrs, 91-120 mo	33.0%	0.0%	0.0%	0.0%	50.0%	100.0%
20001-25000 hrs, 121-150 mo	0.0%	0.0%	0.0%	0.0%	75.0%	100.0%

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NOTE: This is a 0.0-hour job
Note: This program is intended to be implemented at PCR. No labor will be allowed since the repair is at PCR. NOTE: This program does not apply to any transmission that is equipped with the new 456-8268 Gear-Sun, 456-8270 Gear-Planet, and 460-5438 Gear As-Ring. NOTE: This program can not be combined with any other program to repair/rebuild the transmission.