The Transmission Shifter Console Or Shift Gate Needs To Be Modified On Certain Challenger 65, 65B, 65C, 70C, 75, 75C And 85C Tractors Caterpillar

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1262 as the Part Number, "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 "PI1262" 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 February 27, 1995 Service Letter. A change was made to the Service Claim Allowances.

Problem

The transmission control cable and linkage may not be correctly seated. This could cause the machine to move while the transmission control lever is in the neutral position on certain Challenger 65, 65B, 65C, 70C, 75, 75C and 85C Tractors.

Affected Product
Model & Identification Number

Group 1

CH65 (7YC1-1899)

CH65B (7YC1900-2200)

CH75 (4CJ1-634)

Group 2

CH65C (2ZJ1-1687)

CH70C (2YL1-1277)

CH75C (4KK1-1943)

CH85C (9TK1-1461)

Parts Needed

Dealers will need to order parts for this Program.

Group 1

4 - 2D6235 Locknut

1 - 6D0679 Knob

2 - 3E8536 Plug

2 - 3P4347 Spacer

2 - 5P4115 Washer

1 - 2S1382 Spring

6 - 8T4205 Washer-Plate

4 - 4V6981 Screw-Button

1 - 6V8183 Nut-Full

4 - 6V8969 Screw-Button

5 - 0310217 Bolt-Self-Locking

1 - 1214745 Support-Hand

1 - 1214746 Gate

1 - 1221779 Lever Assembly

2 - 1222385 Plate

1 - 1222452 Film-Panel (1222453 for 75)

1 - 1224292 Plate Assembly

1 - 1224293 Plate Assembly

1 - 1224296 Lever

Group 2

4 - 2D6235 Locknut

1 - 6D0679 Knob

1 - 9R2620 Plug

1 - 3S2093 Strap

6 - 8T4205 Washer-Plate

1 - 8T5360 Washer-Hard

4 - 4V6981 Screw-Button

2 - 2Y5671 Washer

1 - 6V8183 Nut-Full

4 - 6V8969 Screw-Button

3 - 0310217 Bolt-Self Locking

1 - 1214740 Plate Assembly (1214741 for 75C and 85C)

1 - 1214742 Lever Assembly-Shift

1 - 1214744 Lever

1 - 1214745 Support-Hand

1 - 1214746 Gate

1 - 1219703 Lever Assembly

1 - 1220711 Film-Panel (1220712 for 75C and 85C)

Action Required

See attached rework procedure.

Owner Notification

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

Service Claim Allowances

NOTE: This is a 2-hour job.

NOTE: U.S. and Canadian Dealers Only - This Program does not qualify for a Type 2 SIMS Report.

Parts Disposition

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

NOTE: 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

Group 1

NOTE: Refer to Illustrations 1, 2, 3 and 4 while performing this rework.

Illustration 2

Illustration 3

Illustration 4

1. Inside the cab remove brown plastic trim piece from right hand console.

2 Remove knobs from all control levers and 4 bolts marked "Y" to loosen the metal plate as shown in Illustration 1.

3. Remove top metal plate from right hand console.

4. Remove rocker switches for three point hitch (if equipped).

5. Refer to Illustration 1 and construct a subassembly as follows:

A. Install film (Item N) to plate assembly (Item I).

B. Remove implement remote float lockouts from old plate assembly and install onto new plate assembly(if equipped). Also remove and install the 3-point hitch depth stop assembly, if so equipped.

C. Install gate (Item D) to plate assembly with 4 washers, screws, and locknuts (Items A, B and C in location marked X).

D. Install hand support (Item J) with 2 washers, and bolts. (Items A and E).

E. On machines without three point hitch install 2 plugs (Item P) onto plate assembly.

6. Remove right hand outside cab access panel. Also remove cover of right hand console and two braces to gain access to control cables.

7. Remove shift lever. The suggested procedure is to disconnect transmission control cable, then remove single bolt holding lever to lower pivot, then remove three bolts holding pivot housing to provide clearance to slide the shift lever off the shaft.

8. Subassemble new shift lever. (Illustration 2). Do not reuse spring. Use Item G as shown.

9. Go inside cab and remove old governor control lever and install new lever (Illustration 3). Do not install knob (Item L) until Step 13.

10. Install shift lever subassembly. Do not attach transmission control cable at this time.

11. Take subassembly from Step 5 into cab. For machines equipped with three point hitch, also take 2 plates (Item Q) into cab. Install rocker switches using the plates (Item Q) to modify the punched opening in the plate assembly. Install plate assembly using four screws (Item O, Illustration 1).

12. Right hand consoles on machines prior to "C Series" must be reinforced to reduce console deflection. Attach plate assembly (Item R) to plate assembly (Item I) using 2 bolts (Item E) and 2 washers (Item H). (Refer to Illustration 4). Using Item R as a marking template, center punch location of two mounting holes on cab plate from below. Remove plate assembly (Item R) and drill two 7.5 mm (.295 in) holes into cab plate. Install plate assembly (Item R) using 2 bolts (Item E), 2 washers (Item H), and 2 screws (Item O).

13. Install plastic trim and control lever knobs.

14. Adjust transmission control linkage. In most cases, the transmission control cable need not be replaced. However, the cable should be inspected for damage, excessive drag, and excessive backlash. If cable replacement is required, follow the linkage adjustment procedure in its entirety. If the cable is not replaced, dimensions (D), (E), and (F) in the transmission linkage adjustment procedure should not need to be adjusted. The bolt (Item E) and washer (Item A) will be used to attach the control cable to the shifter. See View A-A in the linkage adjustment procedure for proper location of washer (Item A).

NOTE: Refer to Illustrations 5, 6 and 7 during the linkage adjustment procedure.

Illustration 5

Illustration 6

Illustration 7

15. Place hand lever (2) (Illustration 5) into the neutral position (Illustration 7, View J-J. If the hand lever does not seat firmly in the "V notch", adjust the bolt dimension (B) to 48±1 mm (1.89±.04 in).

16. Use washers (7) to adjust the switch assembly (5) to a dimension of 2.0±0.5 mm (.079±.020 in) engagement with the plate on bottom of lever assembly (2). Tighten the switch to a torque of 18.5±1.5 N·m(13.7±1.1 lb ft).

17. Remove cable rod end (9) from lever (8).

18. Assemble cable assembly so that dimension (C) (back of rod end to end of exposed threads on cable assembly-upper end) is 14.0±1.5 mm (.55±.06 in). Refer to Illustration 7, View H-H. Tighten the cable nuts to a torque of 38±2 N·m (28±1 lb ft).

19. From the upper end, push cable into sheath until valve spool is in the last detent position. This is the SECOND REVERSE speed position.

20. Pull on cable rod end (9) until valve spool moves two detent positions. This is NEUTRAL position.

21. Place hand lever (2) in neutral position (View J-J). Make certain hand lever seats firmly in the "V notch". If it does not seat in the "V notch", adjust the neutral switch and/or bolt dimension (B) again as described in Step 16.

22. Loosen two bolts (11).

23. Position washer between rod end (9) and lever (8). Install and tighten bolt to a torque of 8±5 N·m (6±4 lb ft). Refer to Illustration 7, View A-A.

24. Gently move bracket (10) up and down to determine center of backlash zone. Tighten two bolts (11). Refer to Illustration 6.

NOTE: If the slot length in bracket (10) is not sufficient to freely move up or down to find center of backlash zone, adjust dimension (D) to 22.0±1.5 mm (.87±.06 in).

25. In the cab, check hand lever position in first forward and first reverse relative to the corners of the "V notch". The distance should be equal (X=Y, Illustration 7, View J-J). Be aware of system backlash when making this comparison.

26. Adjust bracket (10) again, if necessary, as described in Step 24.

27. Move the hand lever into all speed positions to test for proper adjustment. Also check if neutral start switch functions properly.

28. Install the right hand console access panel and cab access panel.

Group 2

NOTE: Refer to Illustrations 8, 9 and 10 while performing this rework.

Illustration 9

Illustration 10

1. Inside the cab remove brown plastic trim piece from right hand console.

2. Remove knobs from all control levers and remove the 4 bolts marked "Y" to loosen the metal plate as shown in Illustration 8.

3. Remove top metal plate from right hand console.

4. Remove the neutral start switch. If equipped, remove cigarette lighter and rocker switches for three point hitch.

5. Refer to Illustration 8 and subassemble the following:

A. Install film (Item N) to plate assembly (Item I).

B. Remove implement remote float lockouts from old plate assembly and install onto new plate assembly. Also remove and install the 3-point hitch depth stop assembly, if so equipped.

C. Install gate (Item D) to plate assembly with 4 washers, screws, and locknuts (Items A,B,C in locations marked X).

D. Install hand support (Item J) with 2 washers, and bolts (Item A,E).

E. On machines without a cigarette lighter, install plug (Item P) onto plate assembly.

6. Remove right-hand outside cab access panel.

7. Remove shift lever by disconnecting transmission control cable and removing three bolts at lower pivot.

8. Subassemble new shift lever. Refer to Illustration 9.

9. Go inside the cab and remove old governor control lever and install new lever. Refer to Illustration 10. Do not install knob (Item L) until Step 12.

10. Install shift lever subassembly. Do not attach transmission control cable at this time. Refer to attached section on linkage adjustment.

11. Take subassembly from Step 5 into cab and install cigarette lighter if equipped.

NOTE: Paint removal from the bottom of the mounting hole may be required to provide grounding for the lighter.

Install three point hitch rocker switches or plugs. Install neutral start switch. Install plate assembly using four screws. Refer to Item O, Illustration 8.

12. Install plastic trim and control lever knobs.

13. Adjust transmission control linkage. The new procedure is attached. In most cases, the transmission control cable need not be replaced. However, the cable should be inspected for damage, excessive drag, and excessive backlash. If cable replacement is required, follow the linkage adjustment procedure in its entirety. If the cable is not replaced, dimensions (D), (E), and (F) in the transmission linkage adjustment procedure should not need to be adjusted. The bolt (Item E) and washer (Item A) will be used to attach the control cable to the shifter. See view A-A in the transmission linkage adjustment procedure for proper location of washer (Item A).

NOTE: Refer to Illustrations 11, 12 and 13 during the linkage adjustment.

Illustration 11

Illustration 12

Illustration 13

14. Remove cable rod end (5) from lever (4).

15. Assemble cable assembly to dimensions (D View I-I), (E) and (F View H-H).

16. From the upper end, push cable into sheath until valve spool is in the last detent position. This is the SECOND REVERSE speed position.

17. Pull on cable rod end (5) until valve spool moves two detent positions. This is NEUTRAL position.

18. Place hand lever (2) in neutral position (View J-J). Make certain hand lever seats firmly in the "V notch". If it does not seat in the "V notch", adjust the bolt dimension (B) to 52±1 mm (2.05±.04 in).

19. Adjust rod end (5) so that rod end bore and hole in lever (4) are aligned (View G-G). Adjustment must account for system backlash by gently pushing and pulling end of cable to determine center of backlash zone.

20. Position washer between rod end (5) and lever (4). Refer to Illustration 13, View A-A.

21. Install and tighten bolt to a torque of 8±5 N·m (6±4 lb ft). Refer to Illustration 13, View A-A. Tighten jam nut to rod end (5) to a torque of 38±2 N·m (28·1 lb ft).

22. In the cab, check the hand lever (2) position in FIRST FORWARD and FIRST REVERSE relative to the corners of the "V notch". The distance should be equal. X=Y (see View J-J). Be aware of system backlash when making this comparison.

23. If necessary, adjust rod end (5) again.

24. As a final check move hand lever (2) into all speed positions to ensure proper adjustment. Also check if neutral start switch functions properly.

25. Install cab access panel.