PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REPLACING THE DIFFERENTIAL HOUSING BOLTS ON CERTAIN 777D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REPLACING THE DIFFERENTIAL HOUSING BOLTS ON CERTAIN 777D OFF-HIGHWAY TRUCKS

Usage:

TEBE3516-00

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17Aug2015

J570

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REPLACING THE DIFFERENTIAL HOUSING BOLTS ON CERTAIN 777D OFF-HIGHWAY TRUCKS
3258		PS90519

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90519" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as 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.

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TERMINATION DATE

31Aug2017

PROBLEM

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The existing 3389622 Bolts in the 3462106 Differential Group can fail on certain 777D Off-Highway Trucks. The bolt failure will result in premature failure of the differential group components.

AFFECTED PRODUCT

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Model	Identification Number
777D	FKR02204-02205, 2207-2208, 2210, 2212

PARTS NEEDED

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Qty	Part Number	Description
1	1M6573	CUP-ROLLER BRG
1	2D6506	SEAL-O-RING
1	2D9457	CONE-SPL TAPERED
8	2K0337	LOCKNUT
2	3D8513	WASHER-THRUST
1	4F2041	CUP-ROLLER BRG
8	5P8248	WASHER-HARD
1	9M2744	CONE-SPL TAPERED
8	3389622	BOLT-D SHAPED HD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Check the static inspection torque for the 2K0337 Locknuts in the differential group and document the readings.

Replace the 3389622 Bolts, 2K0337 Locknuts, and 5P8248 Washers with new 3389622 Bolts, 2K0337 Locknuts and 5P8248 Washers. Tighten the lock nuts to a torque of 430 N-m. Refer to attached Rework Procedure.

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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 %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-15000 hrs, 0-60 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

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NOTE: This is a 20.0-hour job
For After failure, an additional 10 hours of labor is allowed for additional inspecting of Axle group and flushing the system.

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PARTS DISPOSITION

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

Rework Procedure

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Reference: Disassembly & Assembly, "777D Off-Highway Truck Power Train, Media Number - RENR8428."

1. Remove the transmission and transfer gears. Refer to Disassembly and Assembly, "Transmission and Transfer Gears - Remove".

2. Remove the Differential and Bevel Gear group from the axle housing. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Remove".

3. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Disassemble".

4. Position the Differential and Bevel Gear in a suitable fixture.

5. Remove bolts (1), the washers, and locks (2).

Image1.1.1

6. Remove bolts (3) and washers (4). Remove bearing caps (5) and (6) from the differential carrier assembly.

Image1.2.1

7. Attach a suitable lifting device to the differential. The weight of the differential is approximately 249 kg (550 lb).

8. Remove two adjustment rings (8) from the differential.

9. Raise the differential and remove bearing cages (7).

10. Remove the differential from the differential carrier assembly.

11. Turn over the differential. Position the differential on suitable blocks.

Image1.3.1

12. Check the static inspection torque for eight lock nuts (9). Static inspection torque value is 355 N-M. (Document the torque value and add the details in service Claim)

13. Replace all 3389622 Bolts, 2K0337 Locknuts, and 5P8248 Washers with new bolts, locknuts and washers. The torque for the locknuts is 430 N-m.

14. Assemble the Differential and Bevel Gear. Refer to Disassembly and Assembly, "Differential and Bevel Gear - assemble".

15. Install the Differential and Bevel Gear group to the axle housing. Refer to Disassembly and Assembly, "Differential and Bevel Gear - Install