PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR WHEEL DUO-CONE SEALS ON CERTAIN 777F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR WHEEL DUO-CONE SEALS ON CERTAIN 777F OFF-HIGHWAY TRUCKS

Usage:

REBE6495-01

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18Mar2011

(Revised 18Oct2011)

U-109

A-91

D-99

O-103

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*After Failure Only*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE REAR WHEEL DUO-CONE SEALS ON CERTAIN 777F OFF-HIGHWAY TRUCKS
4001 4201		PS52003

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NOTE:

This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS52003" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

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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.

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NOTE:	This Revised Service Letter replaces the 18Mar2011 Service Letter. A change was made to the Termination Date.

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TERMINATION DATE

31Mar2013

PROBLEM

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The outer duo-cone seal can leak on certain 777F Off-Highway Trucks. If the existing outer duo-cone seal leaks, brake cooling oil will leak into the wheel/rim. If the leak is severe enough, oil may run down the sidewall of the inner tire and onto the ground.

AFFECTED PRODUCT

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Model	Identification Number
777F	JRP00277-00658, 660-757, 759-783, 785-945, 947-959, 962, 965-970, 972-976, 978-1160, 1162-2541
777F OEM	JXP00100-00177 WTK00105-00117

PARTS NEEDED

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Qty	Part Number	Description
2	2A3398	GASKET
2	2M9780	SEAL-O-RING
2	3D3295	SEAL-O RING
2	5P4342	SEAL-O-RING
2	7Y0640	SEAL-O-RING
2	9D7986	SEAL
2	9D7987	SEAL
2	9D7988	SEAL
2	9X7550	SEAL-O RING
2	1237268	SEAL-RING
4	1237271	SEAL-RING
2	1243520	SEAL-RING
2	1293719	SEAL-O-RING
4	1757894	SEAL-O-RING
2	2664594	RING-SEAL
2	3144128	SEAL GP-DUO CONE
2	3176441	SEAL GP-DUO CONE
4	3371943	SEAL-RECTANGULAR
2	3564862	RETAINER-SEAL
2	3590854	SEAL-O-RING
2	3638821	SHIM GP-RAIL
2	3646486	HOUSING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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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Remove the rear tires and rims. Refer to Disassembly and Assembly, "Tire and Rim - Remove and Install".

Remove the axle shaft. Refer to Disassembly and Assembly, "Axle Shaft ? Remove and Install".

Remove the final drive. Refer to Disassembly and Assembly, "Final Drive - Remove and Install". Retain the original shim pack.

Remove the wheel. Refer to Disassembly and Assembly, "Rear Wheel, Bearing, and Duo-Cone Seal ? Remove and Install".

Remove the rear brake. Refer to Disassembly and Assembly, Service and Parking Brake (Rear) ? Remove.

Disassemble the rear brake through Step 16 of RENR8311 Service and Parking Brake (Rear) ? Disassemble.

Install the 337-1943 Seals into the brake anchor.

Install the 9D-7986, 9D-7987, 123-7268, and 124-3520 Seals onto the 364-6486 Housing. Assemble the housing to the brake anchor.

Install the 9D-7988, 123-7271, and 266-4594 Seals onto the service brake piston. Install the piston into brake assembly.

Reinstall the dampers, separator plates and friction discs.

Install the 359-0854 Seal into the groove in the anchor and install the brake end plate.

>>>>Note: If the 318-2943 Brake Alignment Tool Group is not available, the splines on the wheel may be used to align the discs. To do this, position the wheel with the splined end up. Use an alternate pressure source attached to the "P" port on the brake anchor to retract the park brake piston. The pressure required to release the park brake is 630 psi. To avoid damage to the piston seals, do not exceed 730 psi. Position the brake discs so that they are centered and aligned as much as possible. Slowly lower the brake onto the wheel splines until all of the brake discs are engaged with the wheel splines. Release the pressure to lock the park brake before lifting the brake from the wheel and installing it onto the spindle.

Install the brake and 5P-4342 Seal onto the spindle. Reattach the brake lines using 175-7894 and 2M-9780 Seals.

With the 1U-9200 Lever Puller Hoists and 138-7574 Link Brackets used in the removal of the brake, pull the brake inward against the spindle stops.

Install the retaining ring into the groove in the spindle. Using a feeler gage, measure the gap between the raised lugs on the brake housing and the retaining ring. Find the maximum thickness that can be inserted snugly between the housing and the retaining ring without having to use excessive force. Remove the retaining ring. Install shims from the 363-8821 Shim Pack equaling the measured thickness +0.00 / - 0.05 mm. Reinstall the retaining ring.

Remove the existing duo-cone seal retainer from the wheel and replace with the 356-4862 Retainer and 7Y-0640 Seal.

Install the inner duo-cone seal retainer and 129-3719 Seal onto the spindle.

Install the 314-4128 and 317-6441 Duo-Cone Seals into the brake, retainers, and wheel.

Reinstall the wheel bearings onto the spindle.

Reinstall the wheel onto the spindle, using the same wheel bearing shim pack that was removed. The wheel bearing preload does not need to be adjusted.

Reinstall the final drive, using the 3D-3295, 9X-7550, and 2A-3398 Seals.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-8000 hrs, 0-36 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-16000 hrs, 37-72 mo	100.0%	0.0%	0.0%	0.0%	0.0%	100.0%

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NOTE: This is a 40.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Parts and labor are to repair both sides. After failure of one side both sides must be repaired to implement this program.

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