PRODUCT SUPPORT PROGRAM FOR REPAIRING FRONT COVER OIL LEAKS ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPAIRING FRONT COVER OIL LEAKS ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS

Usage:

SEBE6135-06

July 4, 1997
(Revised August 2003)
U-180
A-155
AU-138
O-152
TT-13

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*After failure only*	PRODUCT SUPPORT PROGRAM FOR REPAIRING FRONT COVER OIL LEAKS ON CERTAIN 3406E ENGINES USED IN ON-HIGHWAY VEHICLE APPLICATIONS
1162		PS5292

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 "PS5292" 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: Complete PS5291 before administering this program. However, at the dealers discretion, if it is concluded that the engine is also leaking on the left side at or behind the air compressor, this program may be applied at the same time as PS5291.

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 4, 1997 (Revised August 2001) Service Letter. Changes have been made to the Termination Date.

TERMINATION DATE

July 31, 2004

PROBLEM

The front cover plate to block gasket may leak oil on the left side at or behind the air compressor. If a leak is found at the top of the plate to block gasket, refer to PS5291.

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	8T9527	Power Steering Adaptor O-Ring
2	1100004	Air Compressor Mounting O-Ring
1	1439508	Epoxy
1	1439509	Mixing Nozzle (one per engine repair)
1	1075769	Seal

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 hrs 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

1803-010 D 1.3 R&I Air Compressor (2 Cyl)

1803-010-04 1.6 R & I Air Compressor (4 Cyl)

4306-010-PD 0.5 R & I Power Steering Pump and Drive

1801-560 0.2 Cut Sound Suppression Panel

1162-079-MN 0.2 Tighten Bolts

1162-005 0.5 Epoxy

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

Repair Procedure with Front Cover NOT Removed

NOTE: If access to bolt heads is difficult, a hand wrench is recommended.

Remove air compressor.
Cut approximately 2 inches of sound suppression panel along the left side of the block and front plate joint, this will allow application of epoxy along the entire length of the left side of the plate/block joint.
Remove the power steering pump/adaptor.
Tighten the two 3/8 inch bolts. The use of a hand wrench is recommended. See Illustration 1.
Clean the top and left joint area of the engine where the front cover/plate meet the block with 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 surface. Use (black) Scotchbrite to remove as much paint as possible.

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

After the surfaces have 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 2). 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 at the top front joint area of the front cover/plate/block. Apply a bead approximately 6 inches long. Apply another bead along the left side of the front cover/plate/block joint area.
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).
Install the power steering pump/adaptor.
Paint the area of the engine where the epoxy was applied.
Install air compressor.