PRIORITY - PARTS STOCK ACTION NEEDED - HOUSINGS NEED TO BE INSPECTED FOR CHIPS AND BEARINGS NEED TO BE REPLACED IN THE RET ARDER AND TRANSFER GEAR GROUP ON CERTAIN 657E SCRAPERS - PI3459 - MAILED US, CANADA, CACO, COFA, COSA - REVISED 4/90 Caterpillar

(Revised April 1990)
U-50
A-47
AU-49
O-65
PRIORITY
Parts Stock action needed
3106  PI3459
NOTE: This Revised Service Letter replaces the March 16, 1990 Service
Letter. Changes have been made to the notes in the Rework
Procedure and additional Mail Codes have been added.
COMPLETION DATE  

August 31, 1990  March 31, 1991

The retarder and transfer gear groups need to be inspected for chips and the
bearings need to be replaced on certain 657E Scrapers

Model Identification Number
657E 90Z193-196, 198, 199
91Z352, 355-392, 399, 400
The following only if updated according to the Service Letter dated September
6, 1989 - PS4384: Product Support Program For Updating The Dropbox On Certain
657E Scrapers.
657E 90Z1-192
91Z1-351, 353, 354

Dealers will need to order parts for this Program.
***** Parts Stock *****
3 - 8X1042 Shim
3 - 8X1043 Shim
6 - 8X1044 Shim
6 - 8X1045 Shim
***** Affected Product *****
3 - 1B3897 Cone-Roller Brg
3 - 1B3922 Cup-Roller Brg
1 - 9D2734 Gasket
1 - 5F3144 Seal-O Ring
2 - 9H0846 Seal-O Ring
3 - 3J0634 Seal-O Ring
2 - 1L7203 Cone-Roller Brg
2 - 1L7319 Cup-Roller Brg
1 - 8M5266 Seal-O-Ring
1 - 9M5024 Seal-O Ring
3 - 2S6498 Ring-Seal
1 - 8S7928 Seal-Lip Type
1 - 9W3513 Bearing As
3 - 8X1042 Shim
3 - 8X1043 Shim
6 - 8X1044 Shim
6 - 8X1045 Shim
1 - 300060 Cup-Roller Brg
1 - 300061 Cone-Roller Brg

***** Parts Stock *****
Follow the same repair portion of the rework procedure as for the Affected
Product, only do not remove and replace the bearing cups and cones. 8X1040
Retarder And Transfer Gear Groups in parts stock with an "X" stamped by the 3
digit sequence number on the top of the top shaft do not need to be reworked.
See Illustration 2 in the attached procedure for the location of the stamp.
***** Affected Product *****
See the attached procedure.

Not Applicable

***** Parts Stock *****
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Sell)  (C/L) (Sell)
100% 6 0 0  0 0
NOTE: This is a 6-hour job. Submit one claim for all 8X1040 Retarder
and Transfer Gear Groups in parts stock that were reworked as
described in the attached procedure.
***** Affected Product *****
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs.
(D/N) (Sell)  (C/L) (Sell)
100% 12 0 0  0 0
NOTE: This is a 12-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.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach. (1-Rework Procedure)
Rework Procedure
Dropbox (retarder and transfer gear group) Removal Procedure
NOTE: 8X1040 Retarder And Transfer Gear Groups in parts stock with an
"X" stamped by the 3 digit sequence number above the top shaft do
not need to be reworked. See Illustration 2.
1. Drain the oil from the dropbox.
2. Remove the lines from the scavenge pump and remove the scavenge pump.
3. Remove the tube assembly from between flywheel housing and the dropbox.
4. Disconnect the sending unit wires from the retarder valve.
5. Unbolt the retarder valve and move it out of the way.
6. Remove the 8 bolts from the drive tube assembly at the drop box.
7. Install a 5P9736 Link Bracket on the top of the dropbox.
8. Attach a suitable lifting device to the link bracket in the dropbox.
9. Remove the 19 bolts and one nut that holds the dropbox.
10. Remove the dropbox.
Dropbox Repair Procedure
1. Follow the procedures in the Service Manual and disassemble the dropbox.
2. Remove and discard all bearings from the retarder and transfer gear
groups in the Affected Product.
NOTE: Step 2 does not apply to retarder and transfer gear groups in
parts stock.
3. Inspect all gears for damage.
4. Thoroughly clean the housing assembly.
5. Inspect the housing assembly for any metal chips that may be present
behind the pressed in ring. See Illustration 1. When the ring is
pressed into the dropbox housing the ring may cause a broaching effect
and leave metal shavings behind the ring and in the oil passage. Do not
remove the ring. Use a mirror to inspect behind the ring.
6. Refer to Illustration 2 - Part A and Illustration 2 - Part B and the
notes corresponding the callouts on the illustrations to assemble the
dropbox. Install all new bearing cups and cones during assembly. Shim
as described in the notes.
7. Stamp an "X" by the 3 digit sequence number on the top of the top shaft.
See Illustration 2.
****** IMAGE: SEBE4251.01001.001
CAPTION: Illustration 1 - View A - Inspect For Chips Behind Ring
****** IMAGE: SEBE4251.01001.002
CAPTION: Illustration 2 - Location Of Parts
NOTE A
Assembled bearing endplay must be 0.08 +/- 0.05 mm (003 +/-0.002"). Assemble
two bolts into cage and tighten to 34 N.m (25 lb ft) and rotate gear three
revolutions. Tighten two additional bolts to a torque of 34 N.m (25 lb ft)
and rotate gear three more revolutions. Install a 0.48 (0.019") shim pack and
tighten the bolts to a torque of 34 N.m (25 lb ft). To check endplay, rotate
bearings while applying 289 N (65 LB) load to end of shaft and then applying
the load in the opposite direction while rotating the bearings. Change shims
if necessary and check endplay. Tighten bolts to final torque.
NOTE B
To obtain bearing endplay, assemble cage with two bolts and torque to 34 N.m
(25 lb ft). Then rotate gear three revolutions. Tighten the two additional
bolts to a torque of 34 N.m (25 lb ft) and rotate gear three more
revolutions. Loosen all four bolts and tighten two bolts, 180 deg apart, to a
torque of 1.7 N.m (15 lb/in). Rotate gear three revolutions and tighten to a
torque of 3.4 N.m (30 lb in). Rotate gear three more revolutions and again
tighten to a torque of 3.4 N.m (30 lb in). Measure gap between cage and
housing at the two bolts. Average these two measurements and install
shimpack with thickness equal to this average plus 0.18 (0.007"). Final
endplay must be 0.08 +/- 0.05 (0.003 +/-0.002").
NOTE E
Coat splines with 5P0960 Molybdenum Grease at assembly.
NOTE F
Lubricate bolt threads and washer faces with seal installation compound and
tighten to a torque of 875 +/- 75 N.m
NOTE G
Tighten these 11 bolts first. Then tighten the 5F9338 Bolt. Idler shaft
installation must be complete before assembling other gears.
NOTE H
Tighten to a torque of 55 +/- 7 N.m (40 +/- 5 lb ft).
Item Quantity Part No. Description
1 1 8X1092 HOUSING AS
2 19 5P8864 BOLT
3 20 5P8244 WASHER-HARD
4 1 8X1069 CAGE AS
5 6 8X1044 SHIM *
6 22 343557 BOLT-LOCKING
7 44 5M2894 WASHER-HARD
8 1 6P6873 ROTOR-RETARDER
9 3 3J0634 SEAL-O RING *
10 1 300061 CONE-ROLLER BRG *
11 1 300060 CUP-ROLLER BRG *
12 1 6G2596 GEAR
13 3 1B3922 CUP-ROLLER BRG *
14 3 1B3897 CONE-ROLLER BRG *
15 1 9W3513 BEARING AS *
16 1 5F3144 SEAL-O RING *
17 1 8X1055 SHAFT
18 1 8M5266 SEAL-O-RING *
19 1 9M5024 SEAL-O RING *
20 1 8X2141 CAGE
21 3 8X1042 SHIM *
22 2 1L7319 CUP-ROLLER BRG *
23 2 1L7203 CONE-ROLLER BRG *
24 1 8X2107 GEAR
25 1 8M3837 PLUG-DRAIN
26 1 2A3398 GASKET
27 1 8W9728 GEAR
28 1 8X1006 CAGE
29 1 6G2735 FLANGE
30 2 2G0493 WASHER-RETAINING
31 2 5P6712 BOLT-SELF LCK
32 1 8W3600 GEAR
33 1 8X1084 STATOR AS
34 1 8X0993 SPIDER
35 6 308537 BOLT-LOCKING
40 3 2S6498 RING-SEAL *
44 1 8S7928 SEAL-LIP TYPE *
45 2 9H0846 SEAL-O RING *
47 1 9D2734 GASKET *
50 1 8F5838 PLUG
51 1 5B5980 GASKET-COVER
52 3 8X1043 SHIM *
53 6 8X1045 SHIM *
54 1 5F9338 BOLT
55 1 8X1060 NUT AS
56 22 310219 BOLT-SELF LCK
57 1 9W6166 COUPLING AS
58 20 308535 BOLT-LOCKING
59 1 5P8250 WASHER-HARD
Dropbox Installation Procedure
1. Install the 9H0846 Seal on the 8X1040 Gear Group.
2. Install a 5P9736 Link Bracket on the 8X1040 Gear Group and install gear
group in the flywheel housing. Make sure the spider is in alignment with the
spring coupling.
3. Install the 8 bolts that hold the drive tube to the dropbox. Tighten
the bolts to a torque of 435 +/- 20 N.m (321 +/- 15 lb. ft.).
4. Install O-rings in retarder valve and install retarder valve on dropbox.
5. Connect the sending unit wires to retarder valve.
6. Install the O-ring on scavenge pump and install the pump.
7. Install the O-rings on scavenge pump lines and connect the lines.
8. Install the O-ring on tube assembly from flywheel housing to dropbox.
Install the tube assembly.