DPF Temperature Sensor Thread Salvage Procedure for Certain C7 thru C15 On-Highway Engines{108F, 1439, 1919, 7400} Caterpillar

Engine:

C13 (S/N: LEE1-UP)

C15 (S/N: SDP1-UP; B5R1-UP)

C7 (S/N: C7S1-UP)

C9 (S/N: C9S1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you read this information and you understand this information.

Illustration 1	g02538907
(1) Temperature sensor port in DPF (2) Damaged threads

Illustration 2	g02538939
(3) Sensor not fully engaged into the port

The Diesel Particulate Filter (DPF) is being replaced due to threads being damaged in the ports for the temperature sensors. Threads for the temperature sensors may become damaged or stripped and not allow the temperature sensor to thread completely into the port. This Special Instruction contains the procedure needed to salvage the damaged threads in the DPF.

Sensor Thread Salvage Procedure

Instructions for Cleaning/Chasing the Thread on DPF

Use an M14 x 1.5 tap in order to clean the threads of the temperature sensor ports. If the damage cannot be repaired with the tap, repair the threads using a Heli-coil.

Instructions for Repairing the Damaged Threads of the DPF with a Heli-Coil

Items required to make the repair.

• 4C-8413 Thread Repair Kit

• 9/16 inch H.S.S Drill

• Heli-coils

• Starter Tap

• Bottom Tap

• Heli-coil Insert Tool

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Illustration 3	g02538978

1. Drill out the damaged threads by using a 9/16 inch H.S.S Drill. Drill to a depth of 17.78 mm (0.7 inch). Clean out the shavings as needed using the air gun. Refer to Illustration 3.

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Illustration 4	g02539056

2. Tap a 9/16 inch thread into the hole to accept the Heli-Coil. Use an appropriate lubricant while tapping the new threads. Refer to Illustration 4.

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Illustration 5	g02539118
(4) Starting tap (5) Bottom tap

3. Begin with the starter tap (4) until the tap stops, at approximately 12.7 mm (0.5 inch), then use the bottom tap (5).

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Illustration 6	g02539216
(6) Heli-coil

4. Trim the Heli-Coil (6) to fit. Cut 25.4 mm (1 inch) from the Heli-coil, five full threads from the bottom.

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Illustration 7	g02540536
(7) Mandrel of Insert tool

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Illustration 8	g02541196

5. To install the Heli-Coil (6), retract the mandrel (7) and place the Heli-Coil (6) in the Insert tool with the tang (8) end towards the front of the tool.

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Illustration 9	g02540637

6. Rotate the mandrel (7) through the Heli-Coil until the tang is fully engaged in the driving contour. Continue to rotate the mandrel until the Heli-Coil is engaged by 1 or 2 threads into the tapped port.

7. Place the Insert tool squarely against the tapped hole and rotate the mandrel, holding the DPF with one hand until the Heli-Coil is inserted ? to ? turn below the tapped port surface. Do not hold the DPF tightly against work surface. Allow the tool to float.

8. Install the Heli-Coil by rotating the T-bar and holding the hex portion of the mandrel.

Note: If the Heli-Coil is installed too deeply, the lower threads of the Heli-Coil will prevent proper installation of the temperature probe.

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Illustration 10	g02540879

9. Unscrew the mandrel portion of the Insert tool.

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Illustration 11	g02541196

10. The tang (8) must be removed to allow full passage of the screw into the Heli-Coil (6). The tang may be broken cleanly at the notch in the bottom coil using long nosed pliers. Bend the tang up and down to snap off the excess at notch.

11. Insert the temperature sensor into the repaired DPF port to verify the repair.