Product Support Program For Improved Rear Differential Kits And Driveshaft Yokes May Need To Be Installed On Certain 836 Compactors Caterpillar

Product Support Program For Improved Rear Differential Kits And Driveshaft Yokes May Need To Be Installed On Certain 836 Compactors

Usage:

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Caterpillar: Confidential Yellow

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.

NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4019" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.

Termination Date

May 31, 1998

Problem

Improved rear differential kits and driveshaft yokes may be installed on certain 836 Compactors. Updates are available to address differential thrust washer failure, rear differential mounting bolt loosening and yoke leaking.

Affected Product
Model & Identification Number

836 (3RL28-30, 3RL42-44, 3RL47, 3RL49-51, 3RL53, 3RL54, 3RL58, 3RL62, 3RL63, 3RL65, 3RL70, 3RL75, 3RL77, 3RL81, 3RL86, 3RL87, 3RL89, 3RL92, 3RL95-98, 3RL100, 3RL101, 3RL104-109, 3RL111-1000)

Parts Needed

For 3RL1-45 Machines Only

2 - 1334292Seal - Lip Type

2 - 1416791Yoke Assembly

1 - 1466777Kit - Differential

For 3RL46 And Up Machines Only

1 - 6B4370 Cup - Roller Bearing

24 - 4E5831 Bolt

24 - 4E5685 Spacer

1 - 2K5065 Cone - Roller

1 - 1L7518 Cone - Roller

1 - 5P2526 Cup - Roller Bearing

2 - 7S8561 Seal-O-Ring

1 - 8T3013 Seal-O-Ring

4 - 957993 Pin - Parallel

4 - 1320985 Bearing - Sleeve

4 - 1320986 Washer - Thrush

1 - 1392277 Spider

4 - 1392278Pinion - Differential

Action Required

See the attached Rework procedure.

Service Claim Allowances

NOTE: This is a 46-hour job.

Parts Disposition

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

Attach.

(1-Rework Procedure)

Rework Procedure

Rework procedure for 3RL1 to 3RL45

1. Remove guards and rear axle arrangement from machine.

2. Remove 4E1990 Gear Group from rear axle and disassemble.

3. In the 9U0112 Differential Group, replace (4) 9U0116 or 1204871 Washers with (4) 1320986 Washers, (4) 9U0117 Sleeve - Bearing with (4) 1320985 Sleeve Bearing, (4) 8R3976 Pinion - Differential Bevel with (4) 1392278 Pinion - Differential Bevel and (1) 8R2858 Spider with (1) 1392277 Spider.

NOTE: The standard 836 configuration is a standard differential in the rear axle. If the dealer or customer has modified the differential configuration the standard differential must be modified according to Step 3 and all other steps are applicable to the rear differential. If the machine was shipped with a custom shop modification of no-spin differentials in both the front and rear axles perform all steps except Step 3.

4. Replace 8R2754 Differential Carrier Assembly with 1466256 Differential Carrier Assembly. Replace the differential case bearings, 2K5065 Cone, 5P2526 Cup, 1L7518 Cone and 6B4370 Cup. Reassemble the gear group according to Powertrain Specification Manual, SENR2605-04. At this time, replace the 9X7713 Lip Seal with new 1334292 Seal in the 4E1966 Retainer.

5. Reinstall gear group in axle housing with (24) 4E5831 Bolts and (24) 4E5685 Spacers. Tighten the bolts to 230 ± 40 N·m and turn an additional 120 ± 10 degrees.

6. Drill and ream (4) 19.977 mm ± 0.020 mm holes to a depth of 48 mm ± 2mm (depth includes the carrier flange thickness) through the differential carrier flange and into the axle housing casting while the parts are bolted together. The holes should be located on the bolt circle diameter (673.3 mm) and ± 30 degrees from the horizontal. The dowel hole center can be located by measuring in 18 mm from the carrier outside diameter. See Illustrations 1 and 2.

7. Drive (4) 0957993 Dowels into the holes until they bottom. The dowels must be a press fit in both parts to be effective. Use "Locktite" thread lock compound on the dowels to prevent them from backing out.

8. Reassemble axle to vehicle and replace guards.

9. Replace 8R4736 Yoke Assembly on the rear axle.

10. Remove front guard. At the front axle replace the 9X7713 Lip Seal with new 1334292 Seal in the 4E1966 Retainer and replace 8R4736 Yoke Assembly.

11. Replace the guards.

Rework procedure for 3RL46 and Up

1. Remove guards and rear axle arrangement from machine.

2. Remove 4E1990 Gear Group from rear axle and disassemble.

3. In the 9U0112 Differential Group replace (4) 9U0116 or 1204871 Washers with (4) 1320986 Washers, (4) 9U0117 Sleeve - Bearing with (4) 1320985 Sleeve - Bearing, (4) 8R3976 Pinion - Differential Bevel with (4) 1392278 Pinion - Differential Bevel and (1) 8R2858 Spider with (1) 1392277 Spider.

4. Replace the differential case bearings, 2K5065 Cone, 5P2526 Cup, 1L7518 Cone and 6B4370 Cup. Reassemble the gear group according to Powertrain Specification Manual, SENR2605-04. At this time replace the 9X7713 Lip Seal with new 1334292 Seal in the 4E1966 Retainer.

5. Reinstall gear group in axle housing with (24) 4E5831 Bolts and (24) 4E5685 Spacers. Tighten the bolts to 230 ± 40 N·m and turn an additional 120 ± 10 degrees.

8. Reassemble axle to vehicle and replace guards.

9. Replace 8R4736 Yoke Assembly on the rear axle.

10. Remove front guard. At the front axle replace the 9X7713 Lip Seal with new 1334292 Seal in the 4E1966 Retainer and replace 8R4736 Yoke Assembly.

11. Replace the guards.

Illustration 1