PRODUCT IMPROVEMENT PROGRAM FOR REWORKING 271-3763 OR 279-7457 REAR WHEEL GROUPS IN TO 340-4508 OR 340-4509 REAR WHEEL GROUPS ON CERTAIN 772 OFF HIGHWAY TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REWORKING 271-3763 OR 279-7457 REAR WHEEL GROUPS IN TO 340-4508 OR 340-4509 REAR WHEEL GROUPS ON CERTAIN 772 OFF HIGHWAY TRUCKS

Usage:

REBE4595-00

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25Nov2008

U-605

A-500

D-515

O-554

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Safety Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR REWORKING 271-3763 OR 279-7457 REAR WHEEL GROUPS IN TO 340-4508 OR 340-4509 REAR WHEEL GROUPS ON CERTAIN 772 OFF HIGHWAY TRUCKS
4205 4008 7750		PI10727

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NOTE:

This Program must be administered as soon as possible. When reporting the repair, use "PI10727" 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 "PI10727" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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PROBLEM

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The 303-2357 Rear Spindle needs to be replaced with a new 3394948/">339-4948 Rear Spindle and 3393859/">339-3859 Ring on certain 772 Off-Highway Trucks. These 303-2357 Rear Spindle Castings may have been incorrectly manufactured at the supplier. This could result in a structural failure of the wheel group with the potential for serious injury.

AFFECTED PRODUCT

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Model	Identification Number
*****Group 1*****
772	RLB00271-00285, 287, 289-290, 293-295, 298-303, 305, 307-312, 314-320, 322-416, 419-521
772 OEM	J2M00100-00101

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*****Group 2*****
772	RLB00286, 288, 291-292, 296-297, 304, 306, 313, 321

PARTS NEEDED

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Qty	Part Number	Description
*****Group 1*****
2	4D5642	SHIM
16	5P8247	WASHER-HARD
16	8T0357	BOLT
4	1846020	OIL
2	2979546	SEAL GP-DUO CONE
2	3144122	SEAL GP-DUO CONE
2	3393859	RING
2	3394948	SPINDLE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
*****Group 2*****
2	4D5642	SHIM
16	5P8247	WASHER-HARD
16	8T0357	BOLT
4	1846020	OIL
4	2408240	BEARING AS
2	2979546	SEAL GP-DUO CONE
2	3144122	SEAL GP-DUO CONE
2	3393859	RING
2	3394948	SPINDLE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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****Parts Stock ****

Remove all 303-2357 Spindles from dealer parts stock. Cut the lower strut mounts off of the spindle.

****Affected Product****

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Refer to the attached Rework Procedure.

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OWNER NOTIFICATION

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

SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for all parts removed from dealer parts stock.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 32.0-hour job for Group 1

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 32.0-hour job for Group 2

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PARTS DISPOSITION

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****Parts Stock****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. In addition to the normal procedures cut the lower strut mounts off of the spindle immediately.

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****Affected Product****

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. In addition to the normal procedures cut the lower strut mounts off of the spindle immediately.

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COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR REWORKING 271-3763 OR 279-7457 REAR WHEEL GROUPS IN TO 340-4508 OR 340-4509 REAR WHEEL GROUPS ON CERTAIN 772 OFF-HIGHWAY TRUCKS

MODELS INVOLVED - 772 Off-Highway Trucks

Dear Caterpillar Product Owner:

The 303-2357 Rear Wheel Spindles need to be replaced with new 3394948/">339-4948 Rear Wheel Spindles and 3393859/">339-3859 Rings (spacers) on the products listed below. These 303-2357 Rear Spindle Castings may have been incorrectly manufactured at the supplier. This could result in a structural failure of the wheel group with the potential for serious injury. You will not be charged for the service performed.

Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.

Please refer the dealer to their Service Letter dated 25Nov2008 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.

Caterpillar Inc.

Identification #(s)

Attached to 25Nov2008 Service Letter

Rework Procedure

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Rework Procedure

Action Required

Replace (2) 303-2357 Rear Wheel Spindles with (2) new 3394948/">339-4948 Spindles and (2) new 3393859/">339-3859 Rings. The new spindles are designed with an elliptical radius at the inside wheel bearing shoulder. The new ring is installed as a spacer between the shoulder and the wheel bearing (see Image1.1.1). Reuse and Salvage Guidelines will apply. When bearings are reused, special attention to bearing location must be observed and recorded. (re: RHS bearing inner, RHS bearing outer, LHS bearing inner, LHS bearing outer) Reassemble bearings in same location on new spindle.

Image1.1.1

Refer to Disassembly and Assembly media RENR8259 for safety warnings and system pressure releases where appropriate.
Note: The final drives, axles, brake groups, wheels and bearings can be re-installed with Reuse and Salvage Guidelines.

RENR8259
Tire and Rim (Rear) - Remove
SMCS - 4202-011

...Follow steps to remove tires and rims.

Rear Axle Housing and Differential - Remove
SMCS - 3258-011; 3260-011
...Follow steps to remove rear axle housing and differential assembly from the truck except for the following:

1. Remove the lateral control rod at the differential only
2. Remove the rear drive shaft at the differential yoke only.
3. Steps 10, 11, & 12 do not have to be performed.
4. After removing all systems connections and with the rear axle housing and differential assembly properly secured, remove the (12) bolts that secure the A-frame.
Note: These (12) 302-4536 Bolts can be reused in this procedure.

Note: The complete rear axle housing and differential assembly can now be moved as one unit to a clean disassembly and assembly area for rework.

Axle Shaft - Remove
SMCS - 3278-011

...Remove axle shafts.

Differential and Bevel Gear - Remove
SMCS - 3256-011; 3258-011

...Remove the 50 bolts that secure the wheel groups to the differential housing. Move the wheel groups to an upright position resting on the flange face of the spindle.

Final Drive, Brake and Wheel (Rear) - Remove
SMCS - 4051-011; 4251-011; 4267-011

...Remove the final drive
...Remove wheel, and brake group from the spindle.

Parts provided in this Rework Procedure.
Qty Part No. Part Name

(2) 3394948/">339-4948 Spindle
(2) 3393859/">339-3859 Ring
(2) 314-4122 Seal-Duo Cone
(2) 297-9546 Seal-Duo Cone
(2) 4D-5642 Shim Pack
(16)5P-8247 Washer-Hard
(16)8T-0357 Bolt

Note: Cleanliness is an important factor. Before you begin the installation procedure, the exterior of the components should be thoroughly cleaned. This will help to prevent dirt from entering the internal mechanism

Reassemble components as directed in each installation procedure of RENR8259.

See Final Drive, Brake and Wheel (Rear) ? Install

Note: The preload shim pack adder requirement of 0.418 + 0.00 - 0.050mm (0.0160 + 0.000 - 0.0020 inch will be used with new or reused bearings. (See Step 13i). Reassemble bearings in same locations as recorded during disassembly.

...Record new installed spindle data as follows: