PRODUCT SUPPORT PROGRAM FOR REPLACING THE SHROUD ASSEMBLY IN THE OUTPUT TRANSFER GEAR GROUP OF CERTAIN 735 AND 735 T3 ARTICULATED TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE SHROUD ASSEMBLY IN THE OUTPUT TRANSFER GEAR GROUP OF CERTAIN 735 AND 735 T3 ARTICULATED TRUCKS

Usage:

SEBE9419-01

December 1, 2005
(Revised January 2006)
U-381
A-283
D-300
O-317

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*before or* *after failure*	PRODUCT SUPPORT PROGRAM FOR REPLACING THE SHROUD ASSEMBLY IN THE OUTPUT TRANSFER GEAR GROUP OF CERTAIN 735 AND 735 T3 ARTICULATED TRUCKS
3159		PS41953

NOTE: This Program can be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS41953" 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.

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 Revised Service Letter replaces the December 1, 2005 Service Letter. A changes was made to the Affected Product.

Termination Date

December 31, 2007

PROBLEM

The output transfer gears may overheat on certain 735 and 735 T3 Articulated Trucks when the oil level exceeds the full level. The overheated oil may then melt a nonmetallic shroud inside the box and result in plugged oil lube passages.

AFFECTED PRODUCT

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Model	Identification Number
735	AWR00001-Up
735 T3	B1N00001-305

PARTS NEEDED

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Quantity	Part Number	Description
3	2D8009	SEAL-O RING
1	9D8042	SEAL-O RING
1	6F5559	SEAL-O RING
2	8T4121	WASHER-HARD
2	8T4172	BOLT
2	3W9670	BOSS
2	1165897	SEAL-O-RING
2	1554568	SPACER
2	1614229	SHIM PACK
1	1745336	SEAL-O-RING
1	2604519	PLATE
1	2604520	SHROUD AS.
3	2610315	SPACER

ACTION REQUIRED

See the attached procedure.

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
0-5000 Hours 0-Up Months	100%	36	0	0	0	0
5001-8000 Hours 0-Up Months	33.3%	18	0	0	50%	18
NOTE: This is a 36-hour job.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure)

REWORK PROCEDURE

Procedure to install the metal shroud

1. Refer to D & A Procedure RENR5138.

Reference: Disassembly and Assembly, RENR5138, "735 Articulated Truck Power Train", "Output Transfer Gears - Disassemble"

2. Strip the OTG to allow access to the 161-4212 Case Assembly.

3. Drill two new holes (A) into the 161-4212 Case (Front). Use the holes for the former shroud for locating the two new holes. Refer to Illustration 1 and Table 1.

Illustration 1

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Table 1
Dimensions
A	M10 x 1.5 Thro? Spot face 22 mm (0.86 inch) Diameter to a depth of 0.88 mm (0.035 inch).
B	188.6 mm (7.425 inch)
C	19 mm (0.748 inch)

Photo 1

4. Clean case and assemble using instructions from RENR5138.

Illustration 2

Assemble the output transfer gear. Refer to the Disassembly and Assembly that is referenced. Install the new components that are identified in Illustration 2 and Table 2.

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Table 2
New Components
Item	Part Number	Description	Qty
1	8T-4172	Bolt	2
2	8T-4121	Hard Washer	4*
3	3W-9670	Boss	2
4	8T-5005	Bolt	2*
5	260-4520	Shroud	1
6	260-4519	Plate	1
7	155-4568	Spacer	2
* 2 can be reused from the former shroud.