PRODUCT SUPPORT PROGRAM FOR REPAIRING FRONT COVER, PLATE, BLOCK JOINT, AND FAN BRACKET MOUNTING STUD OIL LEAKS ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING FRONT COVER, PLATE, BLOCK JOINT, AND FAN BRACKET MOUNTING STUD OIL LEAKS ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS

Usage:

SEBE6133-08

July 3, 1997
(Revised August 2003)
U-178
A-153
AU-136
S-150
TT-12

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING FRONT COVER, PLATE, BLOCK JOINT, AND FAN BRACKET MOUNTING STUD OIL LEAKS ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS
1162		PS5291

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 "PS5291" 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: Up to 60 months or 500,000 miles, this Program covers this repair. This is 36 months longer than the 3406 On-Highway Vehicle standard warranty. If for any reason this repair is not successful, please call your Caterpillar Service Representative to discuss this matter.

NOTE: This Revised Service Letter replaces the July 3, 1997 (Revised August 2001) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

July 31, 2004

PROBLEM

The front cover, plate, block joint, and fan bracket mounting studs may leak oil. If a leak is found on the left side at or near the air compressor at this time, refer to PS5292. NOTE: Use this program if PS5243 was not successful.

AFFECTED PRODUCT

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Model

Identification Number

3406E

5EK1-Up

6TS1-Up

4AS1-Up

1LW1-Up

5DS1-Up

2WS1-Up

1MM1-Up

PARTS NEEDED

Claimable Parts

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Qty	Part Number	Description
1	1036045	Cam Access Cover O-Ring
2	5M2894	Washer

Non-Claimable Parts

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Qty	Part Number	Description
1	4C4079	Cleaner(Aerosol), 9U6346 Pump Spray) or equivalent
1	1U8846	Gasket Maker
1	1223781	Quick Cure Primer

Service Tools

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Qty

Part Number

Description

9U7255

Adjustable Idler Assembly

-or-

Refer to TIB Dated March 05, 1997

ACTION REQUIRED

If the fan studs are leaking oil, pull the stud and apply a silicon sealant to the stud shank surface.

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

1166-079 2.0 R&I Timing Gear Cover(Peanut), Tighten

Bolts, and Apply Gasket Maker

1237-063 0.5 Grind Grooves(5EK1-UP, 6TS1-UP,

1LW1-14868, 5DS1-572 Only)

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.

NOTE: Some Ford and Western Star Chassis may require an additional 0.5 hours to remove the fan drive. Use SMCS Code 1359-010 ES.

NOTE: If only the fan studs are leaking oil, claim only this repair on labor code 1359-010 for 1.0 hour under this service letter. However, if the studs are leaking and are repaired in conjunction with other repairs in this letter, claim 1.0 hour along with the labor listed above.

PARTS DISPOSITION

Handle the parts in accordance with your Warranty Bulletin on warranty parts handling. Attach. (1-Rework Procedure) Rework Procedure Repair Procedure with Front Cover NOT Removed

Perform the tightening of the front plate retaining bolts. (See Illustration 1)
Remove the front camshaft access cover.
Remove the three bolts and retaining plate that retain the 6I3618 Gear Assembly. Remove the gear assembly.
Remove the bolt, five nuts, and six washers that retain the 6I3621 Idler Gear Stub Shaft Assembly.
Remove the idler gear stub shaft assembly. (On some engines, you may need to take a hammer and brass rod and lightly tap the stud or leave the nut on the stud with the outer edge of the nut flush with the outer edge of the stud and lightly tap the stud) (Illustration 2), towards the block approximately 1/8 of an inch. This will give enough clearance to remove the stub shaft.
(Step 6 is not needed on 1LW14869-Up, 5DS573-Up, 2WS1-Up, 1MM1-Up or if this Service Letter, PS5291, has been previously completed). With stub shaft removed and viewing the back side, use a die grinder and a 1-1/2 inch diameter grinding wheel, Caterpillar reference number 4C3855, to grind two relief channels approximately .020 of an inch deep (make sure the depth is correct). (Illustration 3)
With the 6I3621 Idler Gear Stub Shaft Assembly removed, remove the two 3/8 bolts/washers (0S1594/5M2894) that are located behind the shaft (retain the front plate to block). Clean the oil from the plate, stub shaft, and the two bolts using 4C4079 Cleaner or equivalent.
Apply a Quick Cure Primer (1223781 Pump Spray/4C9500 Aerosol) to bolt shank. Install new 5M2894 Washers. Apply the primer to both sides of the washers. Apply 1U8846 Gasket Maker to both sides of the washers.
Install the two bolts and standard washers. Tighten to 55 +/- 10 Nm (41 +/- 7 lb ft). See Illustration 1, callout (9).
Tighten the 3/8 inch bolt located directly below the idler gear stub shaft with an open end wrench. Tighten the bolt to a torque of 55 +/- 10 Nm (41 +/- 7 lb ft). See Illustration 1, callout (10).
Apply the Quick Cure Primer to the plate surface that the stub shaft will be re-installed on and to the backside of the idler gear stub shaft assembly.
Apply a 1/16 inch bead of 1U8846 Gasket Maker to the back side of the idler gear stub shaft assembly. (See Illustration 3)

NOTE: The oil supply hole to bushing may be blocked if an excessive amount of gasket maker is applied. Do not put any gasket maker in oil supply groove or in the oil supply hole. (See Illustration 3)

Install the idler gear stub shaft assembly. The standard washer is used with the bolt. See Illustration 1, callout (13). Be sure to tighten to a torque of 55 +/- 10 Nm (41 +/- 7 lb ft) on the five nuts and one bolt that retain the idler gear stub shaft assembly (See Illustration 1). Be sure to use the 9U7255 Adjustable Idler Assembly to set the backlash on the idler gear assembly or refer to TIB Dated March 05, 1997.
Install the 6I3618 Gear Assembly using the 3 bolts and retaining plate. Install the front camshaft access cover with the 1036045 O-ring.
Tighten the two 3/8 inch bolts (located on the front right side of the block) to a torque of 55 +/- 10 Nm (41 +/- 7 lb ft). See Illustration 1, callout (15).
Tighten the two 1/2 inch nuts holding the fan drive bracket to the front cover to 100 +/- 10 Nm (75 +/- 7 lb ft). See Illustration 1, callout (16).
Start the engine as soon as possible to avoid having the gasket maker set-up and possibly block the oil supply hole.