Product Support Program For Replacing Aluminum Pistons In Certain 3406E Truck Engines (410 HP And Below) Up to 500,000 Miles Caterpillar

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 "PS5367" 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: This Revised Service Letter, SEBE6291-04, is effective for all repairs after September 1, 1999.

NOTE: This Revised Service Letter replaces the November 3, 1997 (Revised August 1999) Service Letter. Changes have been made to the TERMINATION DATE.

Termination Date

Problem

On trucks with an aluminum piston failure or a failure requiring cylinder head removal, the following guidelines must be followed.

For Engines Having Up To 350,000 Miles Or 42 Months

PISTONS FOUND CRACKED WHILE PERFORMING A REPAIR REQUIRING CYLINDER HEAD REMOVAL:

Aluminum pistons 7E0525 and 1082716, which do not meet reuse guidelines for cracks, as specified on pages 13 and 14 of "Guideline for Reusable Parts and Salvage Operations", SEBF8049-04, may need to be replaced in certain 3406E Truck Engines up to 350,000 miles, 0 to 42 months.

FOR ENGINES HAVING UP TO 350,001 TO 500,000 MILES OR 43 TO 60 MONTHS.

Pistons That Have Failed:

Aluminum pistons 7E0525 and 1082716, which meet a failure definition below, may fail in certain 3406E Truck Engines with 350,001 to 500,000 miles, 43 to 60 months. A failure is defined as a piston which is unable to create compression because of a hole in the crown/crater or has a piece "chunk" missing from the crown.

Affected Product
Model & Identification Number

3406E (5EK1-80006) (Only engine 310 t0 410 horsepower apply)

NOTE: The above engines were built with single piece aluminum pistons. This program does not apply if the engine was previously rebuilt with two-piece pistons.

Parts Needed

1 - 4N1151 Gasket

1 - 5P5846 Seal-O-Ring

1 - 5P8068 Seal-O-Ring

6 - 0R8333 Cylinder Pack

6 - 9Y7735 Bearing

1 - 0619458 Seal-O-Ring

6 - 1003851 Tube Assembly

6 - 1118606 Bolt

1 - 1358810 Gasket Kit

Action Required

Remove six oil spray jets (single spray jet) and six cylinder packs.

Install six 0R8333 Cylinder Packs, six 1003851 Oil Spray Jets (double spray jets) and related gaskets and seals.

Service Claim Allowances

Parts Disposition

TEPS Dealers must return the affected part(s) to their Caterpillar dealer.

Return all cylinder packs with core credit request to:

NOTE: Please do not use the plastic cover when packaging Cylinder Packs for return.

Do Not Return Cylinder Packs if the claim was paid by policy.

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