PSP FOR INCREASING THE WELD ON THE TRANSMISSION TUBE ASSEMBLIES (SLIDE TRACKS), AND INSTALLING BEVEL GEAR, BEVEL GEA R SHAFT BEARING, AND RETAINING BOLTS ON CERTAIN D10N TRACTORS - PS4390 - MAILED US AND CANADA, CACO, CFEL, COSA Caterpillar

U-234
A-151
AU-151
E-101
O-144
3257, 3256  PS4390
NOTE: This Program can be administered either before or after a
failure. In either case the decision whether to apply the
Program is made by the dealer. When reporting the repair, use
"PS4390" as Part Number, "7755" as Group Number, and "96" as
Description Code.

December 31, 1990

***** Group 1 *****
The tapered roller bearings for the bevel gear shaft may fail and the
retaining bolts for the bevel gear may loosen and break on certain D10N
Tractors.
***** Group 2 *****
The stop blocks on the transmission removal tube assemblies (slide tracks)
may be welded incorrectly on certain D10N Tractors. If the weld breaks while
the transmission is being removed from the case and frame assembly, the
transmission may not stop at the end of the slide tracks.

Model Identification Number
***** Group 1 *****
D10N 2YD1-1163
NOTE: Units reworked in the factory were identified with a "D" stamped
on the serial number plate behind the arrangement.
***** Group 2 *****
D10N 2YD1-1205

***** Group 1 *****
1 - 6L9284 Seal-O-ring
3 - 9M9647 Seal-O-ring
2 - 5P9519 Seal-O-ring
1 - 6Y5946 Shaft
1 - 6Y8825 Cage
1 - 6Y8997 Bearing
***** Group 2 *****
Not Applicable

***** Group 1 *****
Part 1
1. Remove the transmission from the vehicle and disassemble it to obtain
access to the bevel gear cross shaft.
2. Remove the bevel gear from the shaft and inspect the gear mounting face
and pilot bore for evidence that relative notion has been occurring
between shafts and gear.
A) If any significant wear/fretting has occurred on the face or the
bore do not reuse the gear.
B) If visual inspection indicates the gear is reusable, the pilot bore
diameter in the gear and the O.D. of the mounting flange on the new
6Y5946 Shaft should be checked to determine that the interference
fit at assembly will be a minimum of .004 mm (.00016") at assembly.
The bore diameter in the original gear used in transmissions with
serial numbers from 1ZE1 to 1ZE1157 (Vehicle PIN 2YD1-977) should
be 245.737 +/- .030 mm (9.6747 +/- .0010"). The O.D. of
-3- December 21, 1989
the shaft flange (gear pilot diameter) should be 245.796 +/- .025
mm (9.677 +/- .001"). If the bore diameter in the gear is too
large to achieve the minimum .004 mm (.00016") interference fit do
not reuse the gear.
Part 2
1. Assemble the original or new gear on the new 6Y5946 Shaft. If the prior
inspection revealed evidence of relative motion between the gear and
shaft, then all new 9S1362 Retaining bolts should be used at assembly.
Tighten the bolts to 475 +/- 50 N.m (350 +/- 37 lb ft).
2. Assemble the new 6Y5946 Shaft with bevel gear in the case assembly
according to the service manual using the new 6Y8997 Bearing Assembly
and the new 6Y8825 Bearing Cage.
****** IMAGE: SEBE4191.00001.001
CAPTION: Illustration 1
***** Group 2 *****
Carefully remove the transmission and inspect the 6Y2446 Tube Assemblies
(slide rails) to see if the plate is correctly welded to the tube. Repair
the weld as necessary. See Illustration 2. The 3mm weld should extend
clockwise from point "A" to "B".
****** IMAGE: SEBE4191.00001.002
CAPTION: Illustration 2

Product Caterpillar Dealer Suggested Customer Suggested
smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
whichever (D/N) (Cost)  (C/L) (Sell)
comes
first
***** Group 1 and 2 *****
0-4000 100% 7.5 0 7.5 0 0
0-24 mo
4001-6000 33 1/3% 3.8 0 3.7 50% 7.5
25-36 mo
NOTE: This is a 15-hour job.
***** Group 2 only *****
0-4000 - 5 0 0 0 0
0-24 mo
4001-6000 - 1.3 0 1.2 0 2.5
25-36 mo
NOTE: This is a 5-hour job.

All parts removed (with the exception of cores used for Caterpillar
Remanufactured parts) should be rendered useless and scrapped immediately
upon completion of the repair.