Rear Accessory Drive Thrust Washer May Be Missing On Certain 3508, 3512, 3516 And 3516B Engines, 777C, 777D, 785B, 789B And 793C Trucks And D11R Tractors 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 "PI3059" 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 "PI3059" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: Refer to your Warranty Bulletin for detailed information with regard to Product Improvement Programs.

Completion Date

Termination Date

Problem

Some 3500 Series Machine Engines built in April, May and June 1997, may be missing a 7N3006 Thrust Washer in the rear accessory drive group. The assembly has two 7N3006 Thrust Washers, with a washer on each side of the cluster gear.

The missing washer is the washer towards the rear side of the flywheel housing.

Affected Product
Model & Identification Number

D11R (8ZR420, 8ZR425, 8ZR426, 8ZR428-431, 8ZR433-450)

777C (8JL68-70)

777D (3PR458-469, 3PR472-482, 3PR484, 3PR488-499, 3PR501, 3PR506-508, 3PR510-514 , 3PR516, 3PR523, 3PR526, 3PR528, 3PR532, 3PR534-543)

785B (6HK760-763, 6HK766, 6HK772-776, 6HK782, 6HK783, 6HK785-787)

789B (7EK626-628)

793C (4AR132, 4AR209, 4AR210, 4AR215-217, 4AR223-232, 4AR234-243)

Remanufactured or Engines Sold through the Parts System

3508 (5TL221-223, 5TL230-232 7YG2069 , 7YG2104, 7YG2106, 7YG2108 5XS170 )

3512 (5EL142 6FL139 , 6FL142, 6FL143, 6FL145)

3516 (6CL246-249 7CL414 , 7CL416, 7CL434, 7CL438, 7CL440)

3516B (7TR365, 7TR408)

Parts Needed

8 - 8B5144 Drive Shaft Bolt (for 777C and 777D)

1 - 5D7523 Seal-O-Ring (for 789B and 793C)

1 - 9H6832 Seal-O-Ring (for D11R, 777C, 777D, 785B)

1 - 8M5255 Seal-O-Ring

8 - 2N2486 Drive Shaft Bolt (for 785B, 789B and 793C)

1 - 7N3006 Washer-Thrust

1 - 7N4320 Gasket

2 - 1V6341 Seal

Action Required

See the attached procedure.

Owner Notification

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

Service Claim Allowances

Labor Hour Breakdown

NOTE: Use a 99Z code to submit a claim on spare components:

NACD 99Z00021

CACo 99Z00621

CBL 99Z00221

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

NOTE: All engines will require an inspection. For those engines needing to be repaired, engines in a chassis should perform Steps 1 through 7. Engines NOT in chassis will only require repair Steps 2 through 6.

Inspection Method:

Remove the RH rear camshaft timing gear cover, 7N4319. Using a mirror and a flashlight or a flexible bore scope, determine if the 7N3006 Thrust Washer closest to the rear of the flywheel housing is missing.

Repair Method:

1. Remove the torque converter from the engine.

2. Remove the engine flywheel.

3. Remove the 7N3005 Idler Shaft from the flywheel housing.

NOTE: Apply a little pressure on the cluster gear when removing the shaft to make sure the front thrust washer remains in position. The cluster gear will only move slightly when the shaft is removed.

4. Install the missing 7N3006 Thrust Washer on the idler shaft.

5. Reinstall the 7N3005 Idler Shaft and thrust bearing onto the flywheel housing.

NOTE: Replace the 8M5255 O-Ring Seal and 1V6341 Sealing washers.

6. Reinstall the engine flywheel.

7. Reinstall the torque converter to the engine.