PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS ON CERTAIN 3126E TRUCK ENGINES Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS ON CERTAIN 3126E TRUCK ENGINES

Usage:

SEBE8492

September 5, 2003
U-237
TT-21

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*Priority*	PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS ON CERTAIN 3126E TRUCK ENGINES
1050		PI30525

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30525" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI30525" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "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.

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COMPLETION DATE	TERMINATION DATE
March 31, 2004	September 30, 2004

PROBLEM

The converter muffler hanger clamps need to be replaced on certain 3126E truck engines. On the affected vehicles built with Caterpillar 3126E 7.2L engines, one or both of the converter muffler clamps may crack or break along a weld bead used to hold the converter muffler assembly to the clamps. If both clamps fail completely, the potential exists that the converter muffler assembly may come loose and fall off the truck.

AFFECTED PRODUCT

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Model

Identification Number

3126E

HEP7843, 7861, 7894, 9557, 9602, 9636, 9650, 9657, 12212, 12238, 12255, 12258, 12275, 12300, 12314, 12329, 12340, 12341, 12358, 12393, 12409, 12431, 12449, 12459, 12470, 12540, 12542, 12543, 12544, 12545, 12547, 12548, 12550, 12551, 12557, 12611, 12620, 12634, 12638, 12644, 12645, 12650, 12725, 12753, 12782, 12812, 12840, 12843, 12845, 12876, 12881, 12895, 12898, 12933, 12935, 12937, 12974, 12978, 12986, 13007, 13029, 13031, 13039, 13081, 13083, 13085, 13086, 13094, 13105, 13109, 13116, 13126, 13130, 13149, 13150, 13154, 13155, 13158, 13163, 13196, 13204, 13212, 13215, 13218, 13221, 13231, 13239, 13241, 13255, 13263, 13273, 13287, 13311, 13317, 13320, 13328, 13331, 13359, 13371, 13386, 13389, 13406, 13411, 13420, 13466, 13468, 13472, 13474, 13475, 13483, 13487, 13488, 13500, 13503, 13507, 13512, 13519, 13532, 13540, 13548, 13559, 13573, 13584, 13590, 13605, 13607, 13608, 13617, 13618, 13622, 13628, 13629, 13632, 13642, 13644, 13651, 13658, 13663, 13672, 13675, 13686, 13690, 13697, 13700, 13703, 13708, 13711, 13714, 13726, 13741, 13748, 13749, 13764, 13765, 13770, 13781, 13786, 13788, 13797, 13798, 13799, 13801, 13803, 13805, 13818, 13821, 13824, 13827, 13834, 13840, 13842, 13844, 13847, 13849, 13854, 13857, 13860, 13863, 13873, 13875, 13888, 13892, 13896, 13901, 13905, 13909, 13914, 13918, 13922, 13928, 13939, 13941, 13945, 13949, 13951, 13953, 13955, 13957, 13968, 13972, 13976, 13979, 13989, 13995, 13999, 14003, 14008, 14017, 14020, 14026, 14032, 14035, 14041, 14044, 14048, 14052, 14058, 14062, 14065, 14067, 14070, 14072, 14075, 14076, 14077, 14078, 14079, 14080, 14081, 14082, 14083, 14085, 14086, 14087, 14089, 14090, 14091, 14092, 14093, 14094, 14095, 14096, 14097, 14098, 14099, 14100, 14101, 14102, 14103, 14104, 14215, 14217, 14219, 14221, 14226, 14228, 14234, 14237, 14240, 14242, 14248, 14255, 14259, 14261, 14263, 14265, 14267, 14269, 14271, 14273, 14275, 14278, 14281, 14285, 14287, 14291, 14293, 14298, 14300, 14302, 14304, 14306, 14308, 14311, 14313, 14315, 14317, 14319, 14321, 14323, 14325, 14327, 14329, 14332, 14335, 14337, 14339, 14341, 14342, 14343, 14346, 14347, 14349, 14352, 14353, 14354, 14364, 14369, 14371, 14372, 14373, 14377, 14381, 14382, 14383, 14385, 14387, 14390, 14391, 14395, 14401, 14402, 14403, 14406, 14408, 14410, 14411, 14416, 14420, 14424, 14427, 14429, 14435, 14436, 14441, 14444, 14450, 14455, 14456, 14460, 14467, 14468, 14470, 14473, 14478, 14506, 14510, 14511, 14526, 14531, 14534, 14537, 14538, 14549, 14551, 14555, 14566, 14568, 14571, 14585, 14595, 14604, 14608, 14613, 14620, 14630, 14639, 14642, 14646, 14653, 14658, 14659, 14660, 14661, 14665, 14667, 14675, 14679, 14682, 14686, 14693, 14694, 14699, 14703, 14704, 14707, 14710, 14713, 14714, 14719, 14723, 14727, 14728, 14731, 14738, 14739, 14740, 14744, 14751, 14752, 14759, 14761, 14766, 14767, 14769, 14775, 14780, 14782, 14801, 14812, 14814, 14824, 14826, 14828, 14840, 14843, 14845, 14847, 14850, 14856, 14861, 14866, 14870, 14874, 14880, 14889, 14895, 14912, 14915, 14917, 14919, 14921, 14925, 14927, 14966, 14969, 14971, 14974, 14976, 14990, 14991, 14995, 15000, 15003, 15006, 15021, 15029, 15041, 15047, 15049, 15058, 15063, 15071, 15085, 15088, 15129, 15149, 15151, 15154, 15157, 15165, 15175, 15179, 15180, 15184, 15186, 15191, 15192, 15193, 15210, 15214, 15215, 15230, 15234, 15236, 15241, 15248, 15259, 15265, 15267, 15275, 15277, 15281, 15283, 15284, 15288, 15306, 15311, 15312, 15314, 15316, 15329, 15331, 15334, 15342, 15344, 15346, 15347, 15358, 15360, 15363, 15367, 15373, 15377, 15379, 15382, 15384, 15392, 15394, 15396, 15399, 15400, 15402, 15404, 15406, 15407, 15411, 15412, 15414, 15416, 15421, 15423, 15424, 15427, 15428, 15430, 15432, 15436, 15441, 15443, 15445, 15447, 15448, 15450, 15452, 15454, 15456, 15458, 15462, 15463, 15465, 15497, 15503, 15507, 15509, 15513, 15518, 15520, 15529, 15531, 15532, 15535, 15539, 15548, 15549, 15553, 15558, 15562, 15563, 15567, 15573, 15576, 15582, 15585, 15589, 15592, 15594, 15599, 15602, 15606, 15607, 15609, 15616, 15617, 15620, 15624, 15626, 15628, 15629, 15631, 15632, 15635, 15640, 15643, 15656, 15660, 15662, 15665, 15670, 15672, 15679, 15686, 15696, 15706, 15709, 15712, 15715, 15717, 15720, 15724, 15726, 15731, 15735, 15739, 15745, 15750, 15760, 15763, 16195, 16718, 16724, 16802, 16831, 16854, 16878, 16883, 16890, 16897, 16912, 16929, 16940, 16955, 16959, 16975, 16977, 16988, 16993, 16995, 17006, 17016, 17023, 17045, 17047, 17087, 17104, 17117, 17144, 17155, 17159, 17172, 17182, 17186, 17188, 17193, 17203, 17205, 17211, 17234, 17236, 17247, 17261, 17282, 17286, 17290, 17302, 17312, 17326, 17328, 17339, 17359, 17374, 17383, 17393, 17409, 17415, 17417, 17419, 17474, 17482, 17494, 17498, 17510, 17513, 17518, 17520, 17525, 17527, 17555, 17591, 17597, 17600, 17606, 17621, 17627, 17644, 17648, 17652, 17652, 17655, 17658, 17661, 17665, 17672, 17675, 17679, 17683, 17698, 17701, 17704, 17712, 17716, 17719, 17723, 17727, 17730, 17749, 17761, 17776, 17795, 17797, 17805, 17831, 17834, 17844, 17862, 17868, 17881, 17884, 17887, 17889, 17893, 17901, 17903, 17911, 17923, 17928, 17945, 17947, 17969, 17981, 17984, 17987, 18004, 18006, 18009, 18018, 18023, 18024, 18026, 18028, 18050, 18054, 18072, 18078, 18080, 18095, 18098, 18116, 18119, 18125, 18157, 18167, 18170, 18180, 18189, 18219, 18232, 18264, 18272, 18286, 18291, 18321, 18340, 18353, 18356, 18370, 19343, 20314, 20330, 20369, 20396, 20414, 20426, 20453, 20464, 20482, 20485, 20506, 20509, 20513, 20521, 20531, 20550, 20553, 20584, 20599, 20627, 20631, 20653, 20656, 20663, 20666, 20681, 20695, 20697, 20703, 20722, 20735, 20749, 20757, 20772, 20783, 20790, 20799, 20802, 20809, 20835, 20838, 20844, 20865, 20878, 20884, 20896, 20905, 20920, 20924, 20938, 20957, 20966, 20972, 20980, 20991, 21003, 21020, 21028, 21034, 21042, 21047, 21050, 21053, 21061, 21065, 21069, 21078, 21092, 21102, 21105, 21120, 21129, 21160, 21163, 21173, 21177, 21206, 21214, 21234, 21260, 21263, 21279, 21287, 21292, 21298, 21309, 21312, 21314, 21316, 21328, 21332, 21334, 21335, 21340, 21345, 21385, 21387, 21388, 21393, 21396, 21405, 21414, 21422, 21426, 21436, 21444, 21445, 21450, 21452, 21461, 21463, 21466, 21467, 21476, 21480, 21490, 21492, 21500, 21503, 21537, 21542, 21553, 21554, 21564, 21566, 21567, 21575, 21600, 21615, 21621, 21648, 21649, 21654, 21658, 21660, 21663, 21666, 21667, 21669, 21673, 21675, 21679, 21682, 21699, 21709, 21717, 21746, 21756, 21775, 21802, 21803, 21820, 21834, 21847, 21859, 21875, 21877, 21889, 21908, 21910, 21915, 21929, 21934, 21937, 21942, 21943, 21946, 21951, 21952, 21955, 21957, 21969, 21971, 21975, 21982, 21989, 22016, 22028, 22055, 22056, 22064, 22078, 22088, 22093, 22109, 22113, 22156, 22164, 22184, 22196, 22214, 22218, 22235, 22238, 22256, 22298, 22301, 22328, 22339, 22377, 22383, 22389, 22395, 22398, 22405, 22408, 22411, 22420, 22442, 22455, 22466, 22482, 22485, 22487, 22493, 22511, 22519, 22528, 22545, 22562, 22567, 22576, 22591, 22598, 22599, 22604, 22610, 22630, 22635, 22676, 22684, 22696, 22719, 22748, 22750, 22752, 22760, 22762, 22763, 22764, 22772, 22790, 22793, 22796, 22797, 22804, 22837, 22843, 22853, 22867, 22871, 22875, 22881, 22884, 22894, 22895, 22898, 22935, 22941, 22942, 22948, 22957, 22971, 22976, 23002, 23005, 23056, 23068, 23071, 23077, 23091, 23093, 23098, 23125, 23135, 23137, 23139, 23165, 23174, 23184, 23203, 23214, 23237, 23240, 23246, 23263, 23275, 23278, 23294, 23298, 23305, 23324, 23334, 23336, 23347, 23352, 23383, 23400, 23401, 23412, 23413, 23425, 23432, 23446, 23448, 23454, 23470, 23475, 23481, 23483, 23506, 23528, 23578, 23584, 23588, 23608, 23642, 23651, 23656, 23659, 23669, 23691, 23694, 23705, 23719, 23720, 23724, 23749, 23764, 23771, 23778, 23823, 23837, 23839, 23855, 23873, 23892, 23905, 23907, 23914, 23920, 23924, 23935, 23939, 23950, 23967, 23973, 23976, 23980, 24013, 24045, 24047, 24059, 24073, 24101, 24118, 24127, 24130, 24138, 24147, 24160, 24162, 24173, 24187, 24190, 24200, 24203, 24242, 24243, 24249, 24294, 24303, 24307, 24309, 24313, 24324, 24331, 24334, 24346, 24355, 24357, 24372, 24390, 24404, 24434, 24437, 24438, 24441, 24452, 24459, 24464, 24466, 24472, 24474, 24478, 24495, 24498, 24500, 24502, 24513, 24524, 24527, 24534, 24538, 24541, 24550, 24552, 24556, 24560, 24562, 24565, 24571, 24577, 24583, 24595, 24608, 24612, 24628, 24632, 24646, 24647, 24654, 24662, 24665, 24669, 24672, 24674, 24680, 24699, 24702, 24707, 24724, 24729, 24750, 24761, 24765, 24788, 24805, 24825, 24829, 24831, 24839, 24852, 24858, 24864, 24871, 24876, 24883, 24888, 24895, 24901, 24907, 24913, 24919, 24926, 24932, 24940, 24946, 24956, 24963, 24968, 24975, 24981, 24987, 24995, 25005, 25012, 25021, 25027, 25032, 25039, 25045, 25052, 25058, 25065, 25071, 25084, 25088, 25092, 25096, 25100, 25106, 25110, 25117, 25120, 25125, 25132, 25137, 25141, 25145, 25150, 25154, 25160, 25168, 25171, 25177, 25183, 25188, 25194, 25199, 25206, 25211, 25215, 25218, 25222, 25229, 25233, 25238, 25242, 25245, 25250, 25252, 25255, 25259, 25263, 25268, 25273, 25277, 25280, 25284, 25288, 25292, 25299, 25304, 25307, 25318, 25322, 25331, 25338, 25344, 25350, 25356, 25361, 25367, 25373, 25379, 25383, 25388, 25394, 25426, 25435, 25439, 25443, 25451, 25455, 25459, 25463, 25467, 25477, 25487, 25492, 25496, 25501, 25505, 25510, 25517, 25520, 25525, 25529, 25537, 25541, 25544, 25549, 25553, 25557, 25561, 25564, 25572, 25576, 25581, 25590, 25594, 25598, 25602, 25606, 25612, 25615, 25620, 25635, 25642, 25661, 25670, 25677, 25685, 25696, 25710, 25722, 25730, 25740, 25750, 25758, 25768, 25777, 25785, 25790, 25799, 25808, 25815, 25822, 25831, 25837, 25843, 25850, 25856, 25861, 25868, 25873, 25879, 25890, 25896, 25902, 25908, 25913, 25918, 25924, 25930, 25937, 25943, 25950, 25956, 25962, 25968, 25974, 25980, 25986, 25992, 25998, 26004, 26009, 26014, 26018, 26022, 26026, 26030, 26035, 26038, 26041, 26045, 26049, 26053, 26056, 26060, 26064, 26067, 26071, 26075, 26078, 26083, 26087, 26091, 26095, 26098, 26101, 26105, 26111, 26115, 26119, 26123, 26127, 26131, 26135, 26138, 26142, 26147, 26151, 26158, 26161, 26166, 26170, 26173, 26178, 26181, 26185, 26189, 26192, 26197, 26201, 26204, 26208, 26212, 26215, 26218, 26223, 26226, 26230, 26234, 26237, 26241, 26244, 26247, 26249, 26255, 26259, 26262, 26268, 26272, 26274, 26278, 26284, 26286, 26290, 26293, 26297, 26300, 26306, 26309, 26311, 26314, 26317, 26320, 26322, 26325, 26328, 26332, 26337, 26341, 26345, 26349, 26352, 26355, 26358, 26361, 26364, 26367, 26370, 26374, 26379, 26383, 26386, 26389, 26392, 26395, 26401, 26405, 26407, 26410, 26413, 26416, 26419, 26422, 26426, 26429, 26431, 26435, 26439, 26443, 26449, 26455, 26458, 26462, 26466, 26468, 26475, 26481, 26484, 26488, 26491, 26497, 26501, 26504, 26510, 26512, 26514, 26522, 26530, 26533, 26538, 26547, 26550, 26555, 26560, 26565, 26567, 26570, 26574, 26578, 26581, 26584, 26587, 26591, 26594, 26599, 26603, 26608, 26612, 26615, 26618, 26621, 26624, 26628, 26632, 26635, 26637, 26641, 26643, 26646, 26649, 26655, 26657, 26659, 26661, 26663, 26665, 26672, 26677, 26682, 26687, 26691, 26695, 26699, 26704, 26708, 26713, 26718, 26723, 26727, 26732, 26737, 26742, 26747, 26751, 26755, 26760, 26765, 26770, 26779, 26784, 26788, 26793, 26798, 26803, 26808, 26813, 26818, 26823, 26828, 26832, 26836, 26841, 26846, 26851, 26856, 26860, 26864, 26871, 26875, 26881, 26889, 26903, 26911, 26918, 26925, 26932, 26937, 26944, 26951, 26963, 26970, 26985, 26992, 26999, 27005, 27011, 27017, 27023, 27030, 27037, 27049, 27058, 27065, 27071, 27078, 27085, 27091, 27096, 27098, 27103, 27110, 27117, 27122, 27128, 27140, 27147, 27154, 27162, 27168, 27173, 27178, 27185, 27192, 27197, 27206, 27213, 27221, 27234, 27246, 27252, 27259, 27265, 27272, 27277, 27282, 27289, 27296, 27301, 27308, 27314, 27321, 27327, 27331, 27337, 27341, 27350, 27355, 27360, 27364, 27369, 27374, 27379, 27391, 27398, 27404, 27408, 27413, 27418, 27424, 27428, 27433, 27438, 27442, 27448, 27457, 27462, 27467, 27476, 27481, 27484, 27489, 27494, 27497, 27502, 27513, 27515, 27518, 27530, 27536, 27542, 27547, 27551, 27558, 27563, 27569, 27575, 27580, 27584, 27590, 27595, 27601, 27607, 27611, 27615, 27620, 27627, 27635, 27641, 27646, 27653, 27659, 27665, 27670, 27678, 27684, 27689, 27696, 27700, 27705, 27711, 27719, 27725, 27729, 27734, 27738, 27747, 27754, 27762, 27770, 27777, 27784, 27791, 27799, 27807, 27812, 27819, 27827, 27834, 27845, 27852, 27860, 27886, 27893, 27895, 27898, 27903, 27907, 27910, 27913, 27917, 27919, 27924, 27927, 27931, 27934, 27938, 27941, 27946, 27949, 27952, 27957, 27960, 27963, 27968, 27971, 27975, 27978, 27982, 27985, 27989, 27993, 27996, 28000, 28004, 28008, 28013, 28016, 28020, 28024, 28027, 28032, 28035, 28039, 28042, 28047, 28051, 28054, 28057, 28060, 28063, 28066, 28070, 28073, 28079, 28084, 28087, 28091, 28096, 28104, 28108, 28112, 28117, 28121, 28127, 28132, 28137, 28142, 28151, 28156, 28161, 28165, 28171, 28176, 28181, 28184, 28188, 28192, 28198, 28202, 28206, 28210, 28214, 28218, 28221, 28225, 28230, 28235, 28239, 28247, 28251, 28253, 28260, 28267, 28275, 28281, 28287, 28293, 28297, 28304, 28318, 28324, 28331, 28342, 28347, 28356, 28364, 28377, 28384, 28403, 28412, 28489, 28505, 28519, 28542, 28558, 28592, 28622, 28636, 28673, 28678, 28682, 28688, 28693, 28698, 28703, 28708, 28719, 28724, 28729, 28739, 28745, 28750, 28755, 28760, 28765, 28776, 28781, 28786, 28796, 28802, 28807, 28819, 28825, 28833, 28837, 28843, 28847, 28851, 28854, 28857, 28860, 28864, 28867, 28871, 28873, 28877, 28879, 28883, 28889, 28892, 28895, 28898, 28902, 28906, 28909, 28912, 28914, 28917, 28920, 28923, 28925, 28929, 28931, 28934, 28937, 28941, 28944, 28949, 28953, 28957, 28960, 28964, 28969, 28981, 28984, 28987, 28993, 28999, 29003, 29006, 29011, 29015, 29023, 29027, 29029, 29033, 29037, 29042, 29044, 29047, 29052, 29066, 29072, 29076, 29077, 29081, 29087, 29090, 29094, 29098, 29102, 29110, 29115, 29120, 29125, 29129, 29133, 29136, 29140, 29144, 29149, 29155, 29160, 29163, 29169, 29174, 29178, 29182, 29186, 29196, 29200, 29203, 29207, 29211, 29216, 29220, 29224, 29229, 29235, 29240, 29243, 29248, 29252, 29255, 29259, 29268, 29273, 29277, 29284, 29287, 29291, 29295, 29299, 29305, 29309, 29314, 29319, 29323, 29326, 29330, 29333, 29337, 29340, 29344, 29347, 29351, 29355, 29358, 29362, 29366, 29370, 29374, 29377, 29382, 29386, 29389, 29397, 29400, 29411, 29416, 29420, 29425, 29429, 29438, 29441, 29443, 29448, 29452, 29456, 29459, 29461, 29464, 29466, 29475, 29482, 29490, 29497, 29506, 29512, 29522, 29528, 29536, 29544, 29553, 29562, 29572, 29581, 29591, 29601, 29612, 29620, 29629, 29637, 29654, 29663, 29669, 29678, 29687, 29701, 29706, 29712, 29717, 29725, 29729, 29734, 29740, 29745, 29752, 29759, 29766, 29772, 29778, 29785, 29792, 29798, 29803, 29817, 29823, 29829, 29835, 29840, 29847, 29854, 29868, 29876, 29882, 29886, 29890, 29895, 29899, 29904, 29909, 29915, 29919, 29925, 29929, 29941, 29944, 29949, 29954, 29959, 29964, 29970, 29975, 29980, 29989, 29995, 29999, 30003, 30008, 30013, 30015, 30019, 30024, 30033, 30037, 30041, 30042, 30048, 30055, 30072, 30103, 30110, 30125, 30141, 30156, 30165, 30174, 30189, 30195, 30201, 30210, 30225, 30233, 30240, 30278, 30292, 30299, 30307, 30313, 30343, 30349, 30355, 30361, 30372, 30385, 30409, 30415, 30450, 30457, 30495, 30522, 30612

PARTS NEEDED

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Qty	Part Number	Description
1	2405916	SERVICE KIT

ACTION REQUIRED

See the attached Rework Procedure.

OWNER NOTIFICATION

U.S. and Canadian owners will receive the attached Owner Notification.

SERVICE CLAIM ALLOWANCES

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Caterpillar		Dealer Suggested		Customer Suggested
Parts	Labor Hrs.	Parts	Labor Hrs.	Parts	Labor Hrs.
100%	1.0	0	0	0	0
NOTE: This is a 1.0-hour job. NOTE: U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report

PARTS DISPOSITION

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

MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach. (1-Owner Notification)
(2-Rework Procedure)

COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS

XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999

PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE CONVERTER MUFFLER HANGER CLAMPS

MODELS INVOLVED - CERTAIN 3126E TRUCK ENGINES

Dear Caterpillar Product Owner:

The converter muffler hanger clamps need to be replaced on the products listed below. The converter muffler hanger clamps used to attach the catalytic converter muffler (CCM) to the chassis on your Ford Super Duty equipped with a Caterpillar 3126E engine may crack and / or break along a weld bead used to hold the converter muffler can assembly stationary to the clamps. If both straps fail completely, the potential exists that the converter muffler assembly may come loose and separate from the truck. You will not be charged for the service performed.

Contact your local Authorized Ford TEPS (Truck Engine Product Support) dealer or any Authorized Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated September 5, 2003 when scheduling this service.

We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.

Caterpillar Inc.

Identification #(s)

Attached to September 5, 2003 Service Letter

Rework Procedure

The proposed field service should be able to be completed without removing the converter muffler from the vehicle. The overall process will be to remove the band furthest from the inlet, replace it with a new band assembly, and repeat with the second band.

Band removal

Cut the band with a grinding wheel at the overlap of the band on the bottom side of the muffler. Cutting the band at the overlap will reduce the potential of damaging the muffler body.

Illustration 1

Illustration 2

Remove the band completely from the muffler by grinding away the weld between the band and the muffler body. Make sure that care is taken not to damage the outer muffler body while removing this weld.

Illustration 3

Illustration 4

Remove the band and clip from the muffler by removing the bolt holding the isolator assembly to the clip.

Installing new band assembly

Slide the new band assembly into place and reinstall the bolt that holds the isolator to the clip.

Illustration 5

Orient the new band assembly so the bolt-together joint is on the bottom side of the muffler opposite the clip and isolator. Hand-assemble the 5/16-18 bolt and nut provided to temporarily hold the new band assembly in place. Torque the bolt holding the rubber isolator to the clip to 30-40 ft-lb. Torque the bolt holding the band assembly together to 14-18 ft-lb. The band assembly should come together fully, but not be deformed excessively.