The Transmission And Axles Need To Be Reworked To Prevent Failures On Certain 545 Wheel Skidders Caterpillar

The Transmission And Axles Need To Be Reworked To Prevent Failures On Certain 545 Wheel Skidders

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Caterpillar: Confidential Yellow

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30039" as the Part number and "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 "PI30039" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the April 29, 2000 Service Letter. Changes have been made to the Service Claim Allowances.

Completion Date

October 31, 2000

Termination Date

April 30, 2001

Problem

The transmission and axles need to be reworked to prevent failures on certain 545 Wheel Skidders. A tooth spacing error on the torque converter lock-up clutch disc can cause failure of the lock-up system, and contamination of the transmission oil. Also, the transmission piston seals can fail, preventing shifting in certain gears. Continuous use of the differential lock system can cause overheating and failure of lock system components.

Affected Product
Model & Identification Number

Group 1

545 (2FZ235-238, 2FZ240-269, 2FZ271-275, 2FZ281-296)

Group 2

545 (2FZ276, 2FZ299, 2FZ302)

Parts Needed

Group 1

3 - 4C5300 Sealant

1 - 4C9507 Compound

8 - 8C7562 Screw - Flat Head

1 - 8E5735 Ring - Seal

1 - 8E5737 Ring - Seal

1 - 8E5742 Ring - Seal

1 - 4H6520 Seal - O-Ring

1 - 4K6804 Seal - O-Ring

4 - 8K1207 Pin - Dowel

1 - 1L7518 Cone - Roller

2 - 9M2008 Ring - Metal

1 - 1P9252 Ring - Seal

2 - 5P8428 Seal - O-Ring

1 - 5P9806 Seal - O-Ring

1 - 4S5816 Ring - Seal

1 - 9S3263 Compound - Locking

1 - 1T1639 Ring

5 - 9W9399 Ring - Seal

5 - 9W9436 Ring - Seal

1 - 9X7743 Seal - Lip Type

1 - 6Y2982 Ring - Seal

5 - 6Y8265 Seal Assembly

10 - 6Y8285 Ring - Seal

2 - 300061 Cone - Roller

1 - 1259794 Seal - O-Ring

16 - 1271960 Screw - Flat Head

3 - 1292342 Washer - Thrust

1 - 1326596 Cone - Spl Rlr

1 - 1487383 Washer - Thrust

2 - 1565198 Seal - O-Ring

1 - 1928212 Repair Kit

Group 2

3 - 4C5300 Sealant

1 - 4C9507 Compound

8 - 8C7562 Screw - Flat H

1 - 4H6520 Seal - O Ring

1 - 4K6804 Seal - O-Ring

4 - 8K1207 Pin - Dowel

1 - 1L7518 Cone - Roller

2 - 9M2008 Ring - Metal S

1 - 1P9252 Ring - Seal

2 - 5P8428 Seal - O-Ring

1 - 5P9806 Seal - O-Ring

1 - 4S5816 Ring - Seal

1 - 9S3263 Compound - Locking

1 - 1T1639 Ring

1 - 9X7743 Seal - Lip Type

1 - 6Y2982 Ring - Seal

2 - 300061 Cone - Roller

1 - 1259794 Seal - O-Ring

16 - 1271960 Screw - Flat Head

3 - 1292342 Washer - Thrust

1 - 1326596 Cone

1 - 1487383 Washer - Thrust

2 - 1565198 Seal - O-Ring

1 - 1928213 Repair Kit - Axles And Torque Converter

Action Required

See the attached procedure.

Owner Notification

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

Service Claim Allowances

Parts Disposition

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

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

545 Transmission and Axle Update

TRANSMISSION REWORK PROCEDURE

PARTS NEEDED FOR TRANSMISSION REWORK:

GROUP 1 & 2

GROUP 1ONLY

NOTE: The 1928212 contains a 1926065 Kit-Transmission, consisting of:

1 - 1737437 Shaft Assembly

1 - 1737438 Shaft Assembly

1 - 1737439 Shaft Assembly

1 - 6Y7951 Disc

The remaining portion of this kit will be used in the Axle Rework.

GROUP 2 ONLY

1928213 Repair Kit, containing a 6Y7951 Disc. The remaining portion of this kit will be used in the Axle Rework.

REFERENCE MATERIAL:

GROUP 1 AND 2 PROCEDURE

Start by removing the transmission. Then separate the torque converter from transmission. See Illustration 1 for the following steps.

1. Remove the transmission cover assembly from the torque converter.

2. Disassemble the torque converter by removing eighteen bolts and washers (1) that hold the rotating housing (5) to the impeller (2).

3. Remove the cover (8) from the rotating housing.

4. Remove the turbine hub (9) from the housing.

5. Remove the plate (4) from the housing by removing bolts and washers (3).

6. Remove the friction disc (6) and the piston (7) from the housing.

NOTE: Inspect the parts for damage. Do not reuse any parts that are damaged. The only part on the impeller side of the converter that really needs to be inspected is the 6Y8449 Thrust Washers.

7. Assemble the converter using the new 6Y7951 Disc in the lockup clutch and new seals.

8. Install the new lip seal in the cover assembly and install the cover on the torque converter.

Group 1 ONLY

The transmission rework consists of replacing three shaft assemblies (173-7437, 173-7438, and 173-7439). All the clutch components will be reused except for the seals so be sure to identify clutch components at disassembly or transfer the components to the new shaft assembly immediately.

See Illustration 2 for Steps 1 and 2.

1. Remove the three clutch groups (2,3,4) from the transmission case.

NOTE: The input group (1) and the output group (5) do not have to be removed from the case.

2. Use the Service Manual as necessary to disassemble each clutch group. Inspect the clutch components for damage. Do not reuse any components that are damaged. Replace each shaft assembly and assemble the clutch components using the new seals.

3. Measure the running clearance of each clutch after assembly. See the procedure 'Transmission Clutch Running Clearance-Check' in the Testing and Adjusting Service Manual, RENR3045.

4. Install the three clutch groups into the transmission case.

GROUP 1 AND 2

1. Replace the three rotating seals (9M2008 & 1P9252) on the input shaft.

2. Connect the torque converter to the transmission.

3. If a test bench is available, test the transmission and torque converter for proper operation. If a test bench is not available, the transmission and torque converter can be tested after installation into the machine

4. Install the transmission into the skidder.

5. Calibrate the torque converter lockup pressure. See the procedure 'Calibrating the Lockup Clutch' in the Testing and Adjusting Service Manual, RENR3045.

6. Check the machine for proper operation.

FRONT AND REAR DIFFERENTIAL REWORK PROCEDURE

GROUP 1 & 2

PARTS NEEDED FOR DIFFERENTIAL REWORK

REFERENCE MATERIAL

GROUP 1 & 2 PROCEDURE

Refer to Disassembly and Assembly, 545 Wheel Skidder Power Train, RENR3046 for safety information, photos, and technical information not provided here. Rework the front differential before starting the rework on the rear differential or keep work separated to prevent mixing of parts. Cleanliness is an important part of assembly. Clean and inspect all parts. Replace any worn or damaged parts.

FRONT DIFFERENTIAL

1. Remove front differential from the skidder.

2. Remove the differential pinion housing subassembly from the axle center housing. Save the shim pack for reuse. Check the subassembly to insure there is no endplay in the pinion shafts bearings. Measure the subassembly bearing rolling torque at the pinion shaft. Document the rolling torque measured for later use.

3. Remove the intermediate housing from the axle center housing.

NOTE: If not required, do not remove the service brake piston from the intermediate housing. Removing and installation may cause seal damage. Weight of the intermediate housing and piston combined is approximately 75.3 kg (165.7lb).

4. Place the intermediate housing with the differential lock piston facing up. Using caution, apply air pressure to the lock piston fitting to separate the piston from the intermediate housing. Remove and discard the lock piston including dowels and piston seals.

5. Press two 8K1207 dowels into one 1843586/">184-3586 differential lock piston so the dowels protrude 19.5 ± 1.0 mm (.76 ± .04 in) from the piston surface. Install one 5P8428 seal-o-ring and one 156-5198 seal-o-ring in the piston. Lubricate the two seals with petroleum jelly. Clean and lubricate the intermediate housing bore with a thin film of petroleum jelly. Install the piston into the intermediate housing by aligning the dowels. Do not allow the piston to bind during installation or the seals may be damaged.

6. Remove the differential and bevel gear from the axle center housing. Remove and discard the 1476234 Thrust Washer. Remove and discard fourteen of the sixteen bolts and washers holding the differential reaction end case to the center case. Slowly loosen the two remaining bolts. Springs inside the differential will force the reaction end case to separate from the center case. Remove and discard the two loosened bolts and washers. Remove and discard the complete reaction end case assembly

7. Remove the 1394128/">139-4128 differential gear, four 1440496 Springs, six 6Y7954 Friction Disc, and seven 7D8185 Disc from the differential center case. Save these parts for reuse. Remove and discard the 8D4282 Disc.

8. Using a suitable lifting devise, turn the differential center case over. Remove and discard the eight bolts and washers holding the gear end case to the center case. Separate the gear end case from the center case. Remove the 9C9748 differential gear, 4V5392 spider, four 8X9499 thrust washers, four 9C6016 pinion gears, and four 151-4809 sleeve bearings. Save these parts for reuse. Discard the center case.

9. Remove the 1394118 Bevel Gear from the differential gear end case. Save the bevel gear, twenty bolts, and twenty washers for reuse. Discard the complete gear end case assembly.

10. Disassemble the 1498125 Case assembly. Clean the case thrust washer contacting surfaces and the thrust washers with a solvent cleaner. Allow parts to dry. Apply a thin coat of 4C9507 retaining compound to the inside case walls where the thrust washers will contact. Install the 1487383 Thrust Washer to the inside of the gear end case with the flat surface against the case. Install one 1292342 Thrust Washer to the inside of the reaction end case with flat surface against the case. Apply a small amount of the 4C9507 Retaining Compound to the threads and tapered heads of eight 127-1960 flat head screws to lock the threads and bond the screw heads to the washers. Install the screws and torque each screw to 12 ± 3 N·m (8.8 ± 2.2 lb. ft). Do not over tighten. Remove any excess retaining compound.

11. Heat the original 1394118 Bevel Gear to a maximum of 135C (275F) for a maximum of 4 hours. Install the gear to the differential end case by aligning the bolt holes. Allow bevel gear to cool to room temperature. Make sure the gear is seated properly. Install the original bolts and washers. Tighten to 270 ± 40 N·m (200 ± 30 lb ft).

12. Install one 030-0061 bearing cone to the differential gear end case. Install the 132-6596 bearing cone to the differential reaction end case. Make sure the bearing cones are fully seated. If you heat the bearing cones, allow the assembled parts to reach a uniform temperature. Then use a driver or a press to seat the bearing cones. The limit for heating the bearing cones is a maximum of 135C (275F) for a maximum of four hours.

13. Install one 030-0061 bearing cone to the differential gear end case. Install the 132-6596 bearing cone to the differential reaction end case. Make sure the bearing cones are fully seated. If you heat the bearing cones, allow the assembled parts to reach a uniform temperature. Then use a driver or a press to seat the bearing cones. The limit for heating the bearing cones is a maximum of 135C (275F) for a maximum of four hours.

14. Using a suitable lifting device, turn the differential case assembly over. Install one 185-6619 plate into the differential center case. This replaces the previously discarded 8D4282 disc.

15. Clean and inspect the original six 6Y7954 friction disc and seven 7D8185 disc. Minimum allowable thickness of the clutch pack is 23.85 mm (0.939 inch). Do not reuse any discs with the following conditions: signs of overheating, missing friction material, oil grooves less than 0.25 mm (0.01 inch), or excessive spline wear. Lubricate the disc with 30W power train oil. Install the clutch pack into the differential center case in correct order with a 7D8185 disc first and last. Install the original 1394128 Differential Gear and four 1440496 Springs.

16. Place the reaction end case over one 1843582 Thrust Ring. Install one 1858779 Plate to the thrust ring. Apply a small amount of the 4C9507 Retaining compound to the threads and tapered heads of four 8C7562 flat head screws to lock the threads and bond the screw heads to the plate. Install the screws and torque each screw to 28 ± 7 N·m (21 ± 5 lb ft). Do not over tighten. Remove any excess retaining compound.

17. Position the differential reaction end case over the center case. Make sure the scribe markings line up on the two cases. Apply 9S3263 Thread Lock Compound to the sixteen bolts that came with the differential case. Install the bolts and washers tightening the bolts to 120 ± 20 N·m (90 ± 15 lb ft). Check that the differential pinion gears and differential side gears rotate freely.

18. Lubricate the differential case assembly bearings with 30W power train oil. Using a suitable lifting device, install the differential case assembly into the axle center housing. Lubricate with 30W power train oil and install the 1503756 Needle thrust bearing onto the differential thrust ring. This replaces the 1476234 Thrust washer previously discarded.

19. Clean the intermediate and center housing mating surfaces. Apply 4C5300 Gasket maker to one of the mating surfaces. Refer to Special Instructions SEHS9693 'Surface Preparation and Application Procedures for Gasket Maker'. Using a suitable lifting device, install the intermediate housing to the center housing aligning the pilot dowels. Install and tighten the four bolts to 100 ± 20 N·m (74 ± 15 lb ft).

20. Install the pinion subassembly to the center housing using the new 4H6520 seal-o-ring and the original shim pack. Install the ten bolts and washers. Tighten the bolts to 300 ± 40 N·m (220 ± 30 lb ft).

21. Setup the assembly for correct bevel gear backlash and correct bearing preload. Check for correct bevel gear contact patterns. Since the pinion shaft subassembly bearings were not replaced, using the original shim pack should produce correct bevel gear contact patterns when the bevel gear backlash is adjusted to correct 0.30 +0.12/-0.10mm (.012 +.005/-.004 in) measured at the bevel gear heel or 0.18 +0.07/-0.06 mm (.007 +.003/-.002 in) measured at the pinion shaft spline. Setup the correct differential bearing preload (when using original pinion shaft bearings and original differential bearing cups). Do this by tightening the differential adjusting nut until the rolling torque measured at the pinion shaft is equal to the pinion subassembly rolling torque measured at step 1 plus 2.0 to 2.8 N·m (17.8 to 25.0 lb in).

22. Complete the front axle assembly and install to the machine.

REAR DIFFERENTIAL

1. Remove the rear differential from the skidder.

2. Remove the differential pinion housing subassembly from the axle center housing. Save the shim pack for reuse. Check the subassemblies to insure there is no endplay in the pinion shaft bearings. Measure the subassembly bearing rolling torque at the pinion shaft. Document the rolling torque measured for later use

3. Remove the intermediate housing from the axle center housing. Note: If not required, do not remove the service brake piston from the intermediate housing. Removing and installation may cause seal damage. Weight of the intermediate housing and piston combined is approximately 75.3 kg (165.7lb).

5. Press two 8K1207 Dowels into one 1843586 Differential Lock piston so the dowels protrude 19.5 ± 1.0 mm (.76 ± .04 in) from the piston surface. Install one 5P8428 Seal - O-ring and one 1565198 Seal - O-ring in the piston. Lubricate the two seals with petroleum jelly. Clean and lubricate the intermediate housing bore with a thin film of petroleum jelly. Install the piston into the intermediate housing by aligning the dowels. Do not allow the piston to bind during installation or the seals may be damaged.

7. Remove the 1416766 Differential Gear, four 1440496 Springs, eight 6Y7954 Friction Disc, and nine 7D8185 Disc from the differential center case. Save these parts for reuse. Remove and discard the 8D4282 Disc.

8. Using a suitable lifting devise, turn the differential center case over. Remove and discard the twelve bolts and washers holding the gear end case to the center case. Separate the gear end case from the center case. Remove the 1292341 Differential Gear, 1292339 Spider, four 1513041 Thrust washers, four 9C6023 Pinion Gears, and four 1514464 Sleeve Bearings. Save these parts for reuse. Discard the center case.

9. Remove the 1429655 Bevel Gear from the differential gear end case. Save the bevel gear, twenty-four bolts, and twenty-four washers for reuse. Discard the complete gear end case assembly.

10. Disassemble the 149-8128 case assembly. Clean the case thrust washer contacting surfaces and the thrust washers with a solvent cleaner. Allow parts to dry. Apply a thin coat of 4C9507 Retaining Compound to the inside case walls where the thrust washers will contact. Install one 129-2342 thrust washer to the inside of the gear end case and one 129-2342 thrust washer to the inside of the reaction end case with flat surfaces against the case. Apply a small amount of the 4C9507 Retaining Compound to the threads and tapered heads of eight 127-1960 flat head screws to lock the threads and bond the screw heads to the washers. Install the screws and torque each screw to 12 ± 3 N·m (8.8 ± 2.2 lb ft). Do not over tighten. Remove any excess retaining compound.

11. Heat the original 142-9655 bevel gear to a maximum of 135C (275F) for a maximum of 4 hours. Install the gear to the differential end case by aligning the bolt holes. Allow bevel gear to cool to room temperature. Make sure the gear is seated properly. Install the original bolts and washers. Tighten to 270 ± 40 N·m (200 ± 30 lb ft).

12. Install the 1L7518 bearing cone to the differential gear end case. Install one 030-0061 bearing cone to the differential reaction end case. Make sure the bearing cones are fully seated. If you heat the bearing cones, allow the assembled parts to reach a uniform temperature. Then use a driver or a press to seat the bearing cones. The limit for heating the bearing cones is a maximum of 135C (275F) for a maximum of four hours.

13. Clean, lubricate with 30W power train oil, and assemble the original differential spider, sleeve bearings, pinion gears, and thrust washers. Install these components into the differential center case. Install the original 129-2341 differential gear and the differential gear end case to the center case. Make sure the scribe markings line up on the two cases. Install the twelve bolts and washers that came with the new case. Tighten the bolts to 270 ± 40 N·m (200 ± 30 lb ft).

14. Using a suitable lifting device, turn the differential case assembly over. Install one 185-6619 plate into the differential center case. This replaces the previously discarded 8D4282 disc.

15. Clean and inspect the original eight 6Y7954 friction disc and nine 7D8185 disc. Minimum allowable thickness of the clutch pack is 31.28 mm (1.2315 inch). Do not reuse any discs with the following conditions: signs of overheating, missing friction material, oil grooves less than 0.25 mm (0.01 inch), or excessive spline wear. Lubricate the disc with 30W power train oil. Install the clutch pack into the differential center case in correct order with a 7D8185 disc first and last. Install the original 1416766 Differential Gear and four 1440496 Springs.

16. Place the reaction end case over one 1843582 Thrust Ring. Install one 185-8779 plate to the thrust ring. Apply a small amount of the 4C9507 Retaining compound to the threads and tapered heads of four 8C7562 flat head screws to lock the threads and bond the screw heads to the plate. Install the screws and torque each screw to 28 ± 7 N·m (21 ± 5 lb ft). Do not over tighten. Remove any excess retaining compound.

17. Position the differential reaction end case over the center case. Make sure the scribe markings line up on the two cases. Apply 9S3263 Thread lock compound to the sixteen bolts that came with the differential case. Install the bolts and washers tightening the bolts to 120 ± 20 N·m (90 ± 15 lb ft). Check that the differential pinion gears and differential side gears rotate freely.

20. Install the pinion subassembly to the center housing using the new 4K6804 seal-o-ring and the original shim pack. Install the twelve bolts and washers. Tighten the bolts to 300 ± 40 N·m (220 ± 30 lb ft).

21. Setup the assembly for correct bevel gear backlash and correct bearing preload. Check the bevel gear for correct contact patterns. Since the pinion shaft subassembly bearings were not replaced, using the original shim pack should produce correct bevel gear contact patterns when the bevel gear backlash is adjusted to correct 0.30 +0.12/-0.10mm (.012 +.005/-.004 in) measured at the bevel gear heel or 0.18 +0.07/-0.06 mm (.007 +.003/-.002 in) measured at the pinion shaft spline.

22. Setup the correct differential bearing preload when using original pinion shaft bearings and original differential bearing cups. This is done by tightening the differential adjusting nut until the rolling torque measured at the pinion shaft is equal to the pinion subassembly rolling torque measured at step 1 plus 2.0 to 2.8 N·m (17.8 to 25.0 lb in).

23. Setup the correct differential bearing preload when using original pinion shaft bearings and original differential bearing cups. This is done by tightening the differential adjusting nut until the rolling torque measured at the pinion shaft is equal to the pinion subassembly rolling torque measured at step 1 plus 2.0 to 2.8 N·m (17.8 to 25.0 lb in).

Illustration 1.