Procedure to Rework Housings for the Installation of New Planetary Bolts{3030, 3064, 3105} Caterpillar

Wheel Loader:

950G Series II (S/N: BAA1-UP)

950G Series II (S/N: AYB1-UP)

950G Series II (S/N: AYD1-UP)

950G Series II (S/N: AYL1-UP; AXR1-UP; AYS1-UP; AXX1-UP)

950G (S/N: 2JS1-UP; 4BS1-UP; 6NS1-UP; 3JW1-UP; 5FW1-UP; 5MW1-UP; 8JW1-UP)

950H (S/N: N1A1-UP; M1G1-UP; J5J1-UP; K5K1-UP)

962G Series II (S/N: BTA1-UP; BAB1-UP; BAC1-UP; BAD1-UP; AYE1-UP; AYG1-UP; AXS1-UP; AXY1-UP)

962G (S/N: BDP1-UP; 3BS1-UP; 5AS1-UP; 5RS1-UP; 4PW1-UP; 6EW1-UP; 6HW1-UP; 7BW1-UP)

962H (S/N: N4A1-UP; M3G1-UP; J6J1-UP; K6K1-UP)

Introduction

This Special Instruction contains the procedure in order to allow clearance for tooling on the transfer case housings for the installation of new bolts. The procedure is effective with the machines that are listed above.

A new 294-0877 Special Bolt and 235-2496 Hard Washer has replaced the 246-6025 Special Bolt on the 255-3686 Transfer Case and the 241-9023 Torque Converter Housing . Refer to Illustration 1, Illustration 2, Illustration 3, Illustration 4, and Illustration 5.

The bolt head of the new bolt is larger than the existing bolt. The bolt head on the new bolts has created clearance problems for the impact socket that is used in order to tighten the bolt.

In order to use an impact socket, the spotface on the 255-3686 Transfer Case and the 241-9023 Torque Converter Housing must be reworked.

The following procedure outlines the steps in order to rework the spotface for the 246-6025 Special Bolt on the 255-3686 Transfer Case and the 241-9023 Torque Converter Housing .

Illustration 1	g01558420
(1) Transfer case (2) Planetary group (3) Torque converter housing

Illustration 2	g01539113
Large head on 294-0877 Special Bolt on the 241-9023 Torque Converter Housing (Six places) (2) Planetary group (3) Torque converter housing

Illustration 3	g01539073
Interference problem with an impact socket

Illustration 4	g01539114
Interference problem on the 255-3686 Transfer Case (Six places) (1) Transfer case (2) Planetary group

Illustration 5	g01540294
Interference problem on the 255-3686 Transfer Case (Three places) (1) Transfer case (2) Planetary group

Procedure

Instructions for Reworking the 255-3686 Transfer Case into the 326-4237 Transfer Case

1. Use a grinder or a milling tool cutter in order to remove the current part number from the 255-3686 Transfer Case .

2. Stamp the new 326-4237 Transfer Case part number onto the case.

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Illustration 6	g01540313

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Illustration 7	g01557073

3. Use a 32 ± 0.5 mm (1.26 ± 0.02 inch) spotface tool in order to machine the spotface surface on six holes. Spot face the six holes to full depth 171.5 mm (6.75 inch) (P) from surface (A) to surface (B). Refer to Illustration 6 and Illustration 7.

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Illustration 8	g01540117

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Illustration 9	g01559636
(C) 32 ± 0.5 mm (1.26 ± 0.02 inch) Spotface surface (D) 32 ± 0.5 mm (1.26 ± 0.02 inch) Spotface surface (E) 32 ± 0.5 mm (1.26 ± 0.02 inch) Spotface surface (F) 116.49 mm (4.587 inch) (G) 109.68 mm (4.319 inch) (H) 95.2 mm (3.75 inch) (J) 128.6 mm (5.06 inch) (K) 146.75 mm (5.778 inch) (L) 63.76 mm (2.510 inch)

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Illustration 10	g01559793
(M) 81.5 ± 0.5 mm (3.21 ± 0.02 inch)

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Illustration 11	g01540126

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Illustration 12	g01540122

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Illustration 13	g01540119

4. Use a 32 ± 0.5 mm (1.26 ± 0.02 inch) spotface tool in order to machine the spotface surface on hole (C), hole (D), and hole (E). Spot face the three holes to depth (M). Refer to Illustration 8 through Illustration 13.

Instructions for Reworking the 241-9023 Torque Converter Housing

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Illustration 14	g01594244

1. Use a 32 ± 1 mm (1.26 ± 0.04 inch) spotface tool in order to machine the spotface surface on six holes.

Instructions for Reworking the 252-9189 Output Housing to Change Level 04

1. Use a grinder or a milling tool cutter in order to remove the change level from the part number on the 252-9189 Output Housing .

2. Stamp the new 04 change level onto the output housing.

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Illustration 15	g01594459

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Illustration 16	g01594461
(C) 32 ± 0.5 mm (1.26 ± 0.02 inch) Spotface surface (D) 32 ± 0.5 mm (1.26 ± 0.02 inch) Spotface surface (E) 32 ± 0.5 mm (1.26 ± 0.02 inch) Spotface surface (F) 116.49 mm (4.587 inch) (G) 109.68 mm (4.319 inch) (H) 95.2 mm (3.75 inch) (J) 128.6 mm (5.06 inch) (K) 146.75 mm (5.778 inch) (L) 63.76 mm (2.510 inch)

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Illustration 17	g01594462
(N) 91.5 ± 0.5 mm (3.60 ± 0.02 inch)

3. Use a 32 ± 0.5 mm (1.26 ± 0.02 inch) spotface tool in order to machine the spotface surface on hole (C), hole (D), and hole (E). Spot face the three holes to depth (N). Refer to Illustration 15 through Illustration 17.