PRODUCT SUPPORT PROGRAM FOR REPAIRING OIL LEAKS AT THE SPACER PLATE ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING OIL LEAKS AT THE SPACER PLATE ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS

Usage:

SEBE6132-06

July 2, 1997
(Revised August 2003)
U-177
A-152
AU-135
O-149
TT-11

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING OIL LEAKS AT THE SPACER PLATE ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS
1221		PS5290

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 "PS5290" 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.

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 July 2, 1997 (Revised July 2001) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

July 31, 2004

PROBLEM

The spacer plate gasket may leak oil at the left and/or right rear corner of the cylinder block on certain 3406E Engines used in on-highway vehicle applications.

AFFECTED PRODUCT

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Model

Identification Number

3406E

5EK1-Up

4AS1-Up

5DS1-Up

6TS1-Up

1LW1-Up

2WS1-Up

1MM1-Up

PARTS NEEDED

Claimable Parts

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Qty	Part Number	Description
1	1439508	Epoxy
1	1439509	Mixing Nozzle (one per engine repair)

Non-Claimable Parts

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Qty	Part Number	Description
1	4C4079	Cleaner-(Aerosol Can) or 9U6346 (Pump Spray) (16 oz. will clean approximately 2 engines)
1	Vinyl Tube	(7 cm or 2 1/2 inches long, 5/16 inch ID) (Caterpillar P/N 5P5995 or equivalent)

Service Tools

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Qty	Part Number	Description
1	1439510	Applicator (includes 1435911 Plunger)

ACTION REQUIRED

See the attached rework 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 (D/N)	Labor Hrs (Cost)	Parts	Labor Hrs	Parts (C/L)	Labor Hrs (Sell)
0-500,000 0-60 mo	100 %	100%	0	0	0	0

Labor Hour Breakdown

Labor

SMCS Code Hours Description

1000-074 0.3 Wash

1000-035 0.2 Troubleshoot

7263-010 0.4 R&I Engine Enclosure (if needed)

1221-005-LH 0.5 Epoxy Spacer Plate (left side)

1221-005-RH 0.2 Epoxy Spacer Plate (right rear side)

1000-031 0.3 Test After

NOTE: Repair times are for this repair only - if any duplicate repairs are completed at this time (same work order), they cannot be claimed.

PARTS DISPOSITION

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

Attach. (1-Rework Procedure) Rework Procedure

Clean the left rear, right rear and back, if possible, (see Illustration 2) of the block to head joint area on the engine using 4C4079 Cleaner. A small brass/wire brush may be needed to remove excessive amounts of oil/dirt build-up. Be sure no oil is left on the surfaces. Use (black) Scothbrite pad to remove as much paint as possible.

NOTE: If you can not use the 4C4079 Cleaner (9U6346 Pump Spray), use a brake cleaner that does not leave an oil residue.

After the surfaces has been thoroughly cleaned, spray a light coat of the 4C4079 Cleaner on them and allow to dry completely (approximately 5 minutes). When applying the epoxy adhesive with a 1439510 Epoxy Applicator, it is recommended to have a 5/16 inch bead. To achieve this, first cut the end of the mixer nozzle to increase the orifice size (See Illustration 1). Using a 2 1/2 inch length of 5/16 inch inside diameter clear vinyl hose (cut one end square and the other at 45 degrees), attach the square end to the mixer nozzle.
Place the tapered end of the hose flat against the spacer plate to block joint and carefully squeeze the trigger of the 1439510 Epoxy Applicator and apply a consistent bead of epoxy on the outside of the joint (See Illustration 2). Apply a second bead right above the first bead which will cover the head gasket joint on the left side only.
Allow the adhesive to set up for at least 30 minutes (surface is not tacky) before starting the engine and moving the truck. Before putting the truck in service, be sure the epoxy has sufficiently cured (firm to the touch).
Paint the area of engine where the epoxy was applied.

Illustration 1

(Using a pair of wire cutters, remove the end from the mixing nozzle.)

NOTE: Cut the end off of the fourth largest diameter of the mixing nozzle. The small vinyl tube will slide onto the end of the mixing nozzle.