A New Torque Converter Cover Needs To Be Installed On Certain 928F And 938F Loaders And IT28F Tool Carriers Caterpillar

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.

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3756" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3756" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Completion Date

Termination Date

Problem

The torque converter cover may fail resulting in a hydraulic thrust on the crankshaft on certain 928F and 938F Loaders and IT28F Tool Carriers.

Affected Product
Model & Identification Number

Group 1

928F (8AK132, 8AK133, 8AK145, 8AK150-152, 8AK155, 8AK167, 8AK168, 8AK183, 8AK202, 8AK208, 8AK214, 8AK215, 8AK219, 8AK222, 8AK225, 8AK236-239, 8AK261, 8AK284, 8AK300, 8AK314, 8AK318, 8AK327, 8AK329, 8AK330, 8AK343, 8AK387 2XL169 , 2XL175, 2XL180, 2XL259, 2XL261, 2XL300-302, 2XL318-320, 2XL352, 2XL353, 2XL355, 2XL369-374, 2XL376-378, 2XL397, 2XL403, 2XL409, 2XL420, 2XL425, 2XL471, 2XL478, 2XL484, 2XL485, 2XL490, 2XL500, 2XL505, 2XL517, 2XL539, 2XL540, 2XL569, 2XL571, 2XL606, 2XL612, 2XL616, 2XL643, 2XL645, 2XL646, 2XL660, 2XL661, 2XL667, 2XL670, 2XL677, 2XL693, 2XL696, 2XL704-706, 2XL741, 2XL744, 2XL747, 2XL749, 2XL750, 2XL753-756, 2XL758)

IT28F (1JL38, 1JL44, 1JL49-53, 1JL57, 1JL59-61, 1JL71-73, 1JL75, 1JL76, 1JL86, 1JL90, 1JL99, 1JL103, 1JL105, 1JL107, 1JL111, 1JL114, 1JL115, 1JL117, 1JL118, 1JL120-122, 1JL124, 1JL125, 1JL135, 1JL136, 1JL141, 1JL142, 1JL144-146, 1JL148, 1JL149, 1JL151, 1JL152, 1JL155-157, 1JL160, 1JL162-164, 1JL166-170, 1JL177 3CL38-40 , 3CL44, 3CL47-49, 3CL51, 3CL53-56, 3CL58, 3CL59, 3CL62-64, 3CL69, 3CL71, 3CL72, 3CL75, 3CL79-82, 3CL84, 3CL86, 3CL89, 3CL90, 3CL92, 3CL94, 3CL97, 3CL100, 3CL103, 3CL104, 3CL108, 3CL110, 3CL111, 3CL116, 3CL118-120, 3CL129, 3CL133-135, 3CL137, 3CL142, 3CL144, 3CL146, 3CL148, 3CL162, 3CL163, 3CL171-174, 3CL176, 3CL179, 3CL183, 3CL187, 3CL191, 3CL192, 3CL194-196, 3CL202, 3CL203, 3CL210, 3CL217, 3CL222, 3CL229, 3CL233, 3CL235, 3CL240, 3CL249, 3CL254, 3CL257, 3CL265, 3CL266, 3CL268, 3CL269, 3CL273, 3CL274, 3CL284, 3CL285, 3CL289, 3CL296, 3CL302, 3CL307, 3CL309, 3CL313-315, 3CL317-321, 3CL325, 3CL328, 3CL329, 3CL334, 3CL337-343, 3CL349, 3CL352-354, 3CL359, 3CL361, 3CL363, 3CL364, 3CL366, 3CL367, 3CL371-375, 3CL380, 3CL382-384, 3CL390-394, 3CL404-406, 3CL414, 3CL426-428, 3CL431-438, 3CL441-443, 3CL455-458, 3CL464, 3CL466, 3CL470, 3CL471, 3CL477, 3CL478, 3CL480, 3CL482, 3CL485-488, 3CL495-502, 3CL507, 3CL508, 3CL513, 3CL521, 3CL523-524, 3CL532-534, 3CL541, 3CL545-549, 3CL551, 3CL553, 3CL554, 3CL556, 3CL557, 3CL559, 3CL565, 3CL567, 3CL568, 3CL570, 3CL571, 3CL578, 3CL579, 3CL581, 3CL583, 3CL587, 3CL588, 3CL590, 3CL591, 3CL600, 3CL609, 3CL611, 3CL614, 3CL616, 3CL619, 3CL620, 3CL628, 3CL629, 3CL633, 3CL635, 3CL643-645, 3CL647-649, 3CL654-656, 3CL658, 3CL662, 3CL664, 3CL669, 3CL670, 3CL672, 3CL675-677, 3CL680, 3CL681, 3CL687, 3CL688, 3CL690-691, 3CL694, 3CL695, 3CL700, 3CL706-708, 3CL710, 3CL713, 3CL714, 3CL719, 3CL725-727)

Group 2

928F (8AK113-131, 8AK134-144, 8AK146-149, 8AK153, 8AK154, 8AK156-166, 8AK169-182, 8AK184-201, 8AK203-207, 8AK209-213, 8AK216-218, 8AK220, 8AK221, 8AK223, 8AK224, 8AK226-235, 8AK240-245, 8AK248-260, 8AK262-283, 8AK285-299, 8AK301-313, 8AK315-317, 8AK319-326, 8AK328, 8AK331-342, 8AK344-386, 8AK388-390, 8AK468 2XL113-125 , 2XL127-159, 2XL161-168, 2XL170-174, 2XL176-179, 2XL181-256, 2XL258, 2XL262-299, 2XL303-317, 2XL321-351, 2XL354, 2XL356-368, 2XL375, 2XL379, 2XL381-396, 2XL398-402, 2XL404-408, 2XL410-416, 2XL418, 2XL419, 2XL421-424, 2XL426-449, 2XL451-470, 2XL472-477, 2XL479-483, 2XL486-489, 2XL491-499, 2XL501-504, 2XL506-516, 2XL518-538, 2XL541-556, 2XL558-568, 2XL570, 2XL572-605, 2XL607-611, 2XL613-615, 2XL617-642, 2XL644, 2XL647-649, 2XL651-659, 2XL662-666, 2XL668, 2XL669, 2XL671-676, 2XL678-692, 2XL694, 2XL695, 2XL697, 2XL703, 2XL707-740, 2XL742, 2XL745, 2XL746, 2XL748, 2XL751, 2XL752, 2XL757, 2XL759-875, 2XL878-886, 2XL888, 2XL892)

IT28F (1JL36, 1JL37, 1JL39-43, 1JL45-48, 1JL54-56, 1JL58, 1JL62-70, 1JL74, 1JL77-85, 1JL87-89, 1JL91-98, 1JL100-102, 1JL104, 1JL106, 1JL108-110, 1JL112, 1JL113, 1JL116, 1JL119, 1JL123, 1JL126-134, 1JL137-140, 1JL143, 1JL147, 1JL150, 1JL153, 1JL154, 1JL158, 1JL159, 1JL161, 1JL165 3CL36 , 3CL37, 3CL41, 3CL42, 3CL45, 3CL46, 3CL50, 3CL52, 3CL57, 3CL60, 3CL61, 3CL65-68, 3CL70, 3CL73, 3CL74, 3CL76-78, 3CL83, 3CL87, 3CL88, 3CL91, 3CL93, 3CL95, 3CL96, 3CL98, 3CL99, 3CL101, 3CL105-107, 3CL109, 3CL112-115, 3CL117, 3CL121-128, 3CL130-132, 3CL136, 3CL138-141, 3CL143, 3CL145, 3CL147, 3CL149-161, 3CL164, 3CL170, 3CL175, 3CL177, 3CL178, 3CL180-182, 3CL184-186, 3CL188-190, 3CL193, 3CL197-201, 3CL206-209, 3CL212-216, 3CL218-221, 3CL223-228, 3CL230-232, 3CL234, 3CL236-239, 3CL241-248, 3CL250-253, 3CL255, 3CL256, 3CL258-264, 3CL267, 3CL270-272, 3CL275-282, 3CL286-288, 3CL290-292, 3CL294-295, 3CL297-301, 3CL303-306, 3CL308, 3CL310-312, 3CL316, 3CL322-324, 3CL327, 3CL330-333, 3CL335, 3CL344-348, 3CL350, 3CL351, 3CL355-358, 3CL360, 3CL362, 3CL365, 3CL368-370, 3CL376-379, 3CL381, 3CL385-389, 3CL395-401, 3CL403, 3CL407-413, 3CL415-425, 3CL429, 3CL430, 3CL439, 3CL440, 3CL444-450, 3CL452-454, 3CL459-463, 3CL465, 3CL467-469, 3CL472-476, 3CL479, 3CL481, 3CL483, 3CL484, 3CL489-494, 3CL503-506, 3CL509-512, 3CL514-520, 3CL522, 3CL525-531, 3CL535-540, 3CL542-544, 3CL550, 3CL552, 3CL555, 3CL558, 3CL560-564, 3CL566, 3CL569, 3CL572-577, 3CL580, 3CL582, 3CL584-586, 3CL589, 3CL592-599, 3CL601-605, 3CL607, 3CL608, 3CL610, 3CL612, 3CL613, 3CL615, 3CL617, 3CL618, 3CL621-626, 3CL630-632, 3CL634, 3CL636-642, 3CL646, 3CL650-653, 3CL657, 3CL659-661, 3CL663, 3CL665-668, 3CL671, 3CL673, 3CL674, 3CL678, 3CL679, 3CL682-686, 3CL689, 3CL692-693, 3CL696-699, 3CL701-705, 3CL709-Up, 3CL711, 3CL712, 3CL715-718, 3CL720-724, 3CL728-848, 3CL850-860, 3CL864, 3CL867, 3CL876, 3CL881)

Group 3

938F (1KM142-272, 1KM275-284, 1KM286, 1KM292-294, 1KM298, 1KM627 2RM142-144 , 2RM147)

Parts Needed

Dealers will need to order parts for this Program.

Group 1

2 - 8C5176 Seal-O-Ring

5 - 8E3416 Bearing-Sleeve

1 - 8E3433 Bearing-Sleeve

1 - 8E3435 Bearing-Sleeve

1 - 5F8000 Seal-O-Ring

1 - 1H6227 Seal-O-Ring

1 - 2H3088 Seal-O-Ring

1 - 3J1907 Seal-O-Ring

2 - 4J0520 Seal-O-Ring

1 - 6J2680 Seal-O-Ring

5 - 5K9090 Seal-O-Ring

1 - 2M2561 O-Ring

1 - 2M9780 Seal-O-Ring

1 - 1P3707 Seal-Rectangular

1 - 4P2843 Pulley

1 - 1S3311 Ring-Retainer

1 - 1S4760 Vee Belt Set

10 - 3S2093 Strap-Cable

1 - 1T2018 Cover

1 - 9T5916 Filter-Oil

1 - 1U8846 Gasket Maker

11 - 6V8397 Seal-O-Ring

6 - 1270576 Coil Assembly

Group 2

2 - 8C5176 Seal-O-Ring

5 - 8E3416 Bearing-Sleeve

1 - 8E3433 Bearing-Sleeve

1 - 8E3435 Bearing-Sleeve

1 - 5F8000 Seal-O-Ring

1 - 1H6227 Seal-O-Ring

1 - 2H3088 Seal-O-Ring

1 - 3J1907 Seal-O-Ring

2 - 4J0520 Seal-O-Ring

1 - 6J2680 Seal-O-Ring

5 - 5K9090 Seal-O-Ring

1 - 2M2561 O-Ring

1 - 2M9780 Seal-O-Ring

1 - 1P3707 Seal-Rectangular

1 - 1S3311 Ring-Retainer

10 - 3S2093 Strap-Cable

1 - 1T2018 Cover

1 - 9T5916 Filter-Oil

1 - 1U8846 Gasket Maker

11 - 6V8397 Seal-O-Ring

6 - 1270576 Coil Assembly

2 - 8C5176 Seal-O-Ring

5 - 8E3416 Bearing-Sleeve

1 - 8E3433 Bearing-Sleeve

1 - 8E3435 Bearing-Sleeve

1 - 5F8000 Seal-O-Ring

1 - 1H6227 Seal-O-Ring

1 - 2H3088 Seal-O-Ring

1 - 3J1907 Seal-O-Ring

2 - 4J0520 Seal-O-Ring

1 - 6J2680 Seal-O-Ring

5 - 5K9090 Seal-O-Ring

1 - 2M2561 O-Ring

1 - 2M9780 Seal-O-Ring

1 - 1P3707 Seal-Rectangular

1 - 1S3311 Ring-Retainer

10 - 3S2093 Strap-Cable

1 - 1T2018 Cover

1 - 9T5916 Filter-Oil

1 - 1U8846 Gasket Maker

11 - 6V8397 Seal-O-Ring

6 - 1270577 Coil Assembly

Action Required

Parts Stock

Remove all 3E8588 and 9X7876 Coil Assemblies and 1T1795 Covers from Parts Stock.

Affected Product

See the attached procedure.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

Parts Stock

Submit one claim for all 3E8588 and 9X7876 Coil Assemblies and 1T1795 Covers removed from Parts Stock.

NOTE: US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00001 in the Product Identification Number Field.

Affected Product

NOTE: This is a 30-hour job.

NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.

Parts Disposition

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

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

Group 1

1. Remove the transmission from the vehicle.

2. Replace the 1T1795 Cover on the front of the converter with a new 1T2018 Cover, 1S3311 Snap Ring and 2M2561 O-Ring. The O-ring goes under the cover to make sure the cover does not rotate.

NOTE: If the 1T1795 Cover is cracked, check the engine crankshaft endplay to determine if engine damage has occurred.

3. Drill out the two 5 mm diameter holes in the rotating housing to 12.5 mm as shown in Illustration 1. Because the 1T1866 Rotating Housing is balanced, it is important that the two holes are the same size and 5.0 mm holes are used as a pilot for the 12.5 mm drill.

4. Disassemble the transmission following the instructions in the Service Manual. Replace all the sleeve bearings in the clutch hubs after polishing the sleeve bearing journals on the clutch shafts to a surface finish similar to that of a crankshaft bearing journal or a wrist pin. Polish both journals on all three clutch shafts using the following procedures:

A. Disassemble each clutch group to the basic shaft assembly.

B. Put a center in the chuck journal of a lathe and a live center in the tailstock.

C. Mount the shaft between the centers of the lathe.

NOTE: Do not chuck on the shaft or use a drive dog as it may damage the surface.

D. Start the polishing operation using 1U8282 Emery Paper and several drops of oil. Run the lathe at approximately 500 RPM. To improve the polishing efficiency, oscillate the emery paper across the journal while the shaft is turning. Continue the process for a minimum of five minutes. The shaft size will not be changed, and you cannot over-polish the journals.

NOTE: Use Caterpillar emery paper as other emery paper may not produce the same results.

E. Stop the lathe and wipe the journals off with a clean towel. Repeat Step D using 1U8283 Emery Paper for a minimum of 5 minutes.

F. Repeat Step E using 4C8510 Crocus Cloth for a minimum of 5 minutes.

G. After polishing, be sure to wash the shafts and flush the lube holes.

5. Replace all hub sleeve bearings.

6. If PS8113, Service Letter dated April 3, 1994, has not been performed or if the existing clutch pistons are of the design that has a 6Y8263 Seal Assembly bonded to them, replace each of them with the new loose-lip design 1141071 Piston, 9W9399 I.D. Seal and 9W9436 O.D. Seal when the clutch groups are assembled. If the existing pistons are already the new loose-lip design 1141071 Pistons, (or PS8113 has been performed) proceed to Step 9. Refer to Illustration 2.

NOTE: Illustration 2 provides additional information that will help in the installation of the new piston. If the piston hangs up, you need to make sure the chamfer on the shaft is smooth. You may need to polish the shaft, but the piston bore must be cleaned or the debris could cause a failure. It is also possible to use .002 inch or less shim stock around the shaft to prevent the I.D. seal from hanging up. Do not force the piston in because the seals will be damaged. After assembling each clutch group, test for leaks by applying air pressure in the hole next to the rotating seals. When assembling the 8E3705 first and third shaft assembly into the case, be sure the 8E8321 Thrust Disc does not fall off the shaft. Use grease to hold it in place. If the transmission output cannot be rotated by hand after the transmission has been assemble, the 8E8321 Thrust Disc is probably not in the proper location.

7. The 6B3645 Snap Ring used on the first speed clutch group should be checked for burrs. If a burr is found, it needs to be removed. Refer to Illustration 3.

8. The control manifold needs to have a section of wall removed on the bottom side. This modification will reduce P3 pressure by 10 psi. Refer to Illustration 4.

9. Assemble the clutch groups. After assembling the clutch groups, test for leaks by applying air pressure in the hole next to the rotating seals.

10. Finish assembling the transmission.

11. Replace the six 9X7876 Coil Assemblies with six new 1270576 Coil Assemblies. Tighten the coil assembly nuts to a torque of 20 ± 2.5 N·m (15 ± 2 lb. ft.). Be careful not to over tighten the nuts because the coil assemblies can be damaged.

NOTE: Some of the early machines used the 3E6269 Solenoid Valve Group which used an 8C5576 Coil Assembly. These units do not require the coil update. The 1270576 Coil Assembly does not fit correctly on the 3E6269 Valve Group.

12. Replace the existing crankshaft pulley, used to drive the fan, with a new 4P2843 Pulley. Replacement of this pulley also requires the installation of a new 1S4760 Vee Belt Set.

13. Finish assembling the machine.

Group 2

The rework procedures for Group 2 are the same as the procedures for Group 1 with the exception of Step 12. Machines in Group 2 DO NOT need a new crankshaft pulley or vee belt set.

Group 3

The rework procedures for Group 3 are the same as the procedures for Group 1 with the exceptions of Steps 11 and 12. For Step 11, substitute the following procedure:

11. Replace the six 3E8588 Coil Assemblies with six new 1270577 Coil Assemblies. Tighten the coil assembly nuts to a torque of 20 ± 2.5 N·m (15 ± 2 lb. ft.). Be careful not to over tighten the nuts because the coil assemblies can be damaged.

Step 12 should be eliminated completely. Machines in Group 3 DO NOT need a new crankshaft pulley or vee belt set.

1T-1866 Rotating Housing
Illustration 1

Illustration 2

Illustration 3

Illustration 4