PRODUCT SUPPORT PROGRAM FOR REPLACING THE PINION GEAR AND BEVEL GEAR BOLTS ON CERTAIN 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE PINION GEAR AND BEVEL GEAR BOLTS ON CERTAIN 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS

Usage:

TEBE3889-08

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09Dec2015

(Revised 14Dec2018)

U-657

A-475

D-579

O-568

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After Failure Only	PRODUCT SUPPORT PROGRAM FOR REPLACING THE PINION GEAR AND BEVEL GEAR BOLTS ON CERTAIN 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS
3258 3011 3269 3281 3256		PS53093

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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 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 "PS53093" 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.

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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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NOTE:	This Revised Service Letter replaces the 09Dec2015 (Revised 16Apr2018) Service Letter. Changes have been made to the Termination Date.

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TERMINATION DATE

30Jun2019

PROBLEM

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The 149-2835 Bolts that retain the pinion gear to hub and the 160-0020 Bolts that retain the bevel gear to the housing have experienced failures on certain 797, 797B, 797F, and 797F XQ Off-Highway Trucks. Failures can lead to loosening of the bolted joint causing unwanted downtime.

AFFECTED PRODUCT

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Model	Identification Number
797	5YW00197-00201, 203-209, 213-218, 221-222, 240, 244-250, 254-257, 260-269
797B	JSM00123-00488
797F	LAJ00141-00621
797F XQ	WSP00100-00129

PARTS NEEDED

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Qty	Part Number	Description
4	1A5350	CLIP
1	2S4078	SEAL-O-RING
2	2Y5829	NUT-HEX
4	3E4353	WASHER-HARD
3	3E8004	BOLT-HEX HEAD
4	3G1229	SHIM
4	3G1230	SHIM
4	3G1231	SHIM
4	4D7536	LOCK-NUT
1	5F6222	SEAL-O-RING
3	5K9241	ELBOW
1	5P5846	SEAL-O-RING
40	5P6604	WASHER-HARD
1	5P6718	SEAL-O-RING
2	5P7701	SEAL-O-RING
2	5P7815	SEAL-O-RING
73	5P8245	WASHER-HARD
7	5P9085	CLIP-LOOP
4	6J7855	RING-RETAINING
1	6V0460	CUP-RLR BRG
2	6V1819	BOLT
1	6V1820	BOLT
1	6V3830	SEAL-O-RING
9	6V4589	SEAL-O-RING
12	6V5219	BOLT-HEX HEAD
1	6V5266	SEAL-O-RING
1	6V5759	SEAL-O RING
22	6V5839	WASHER-HARD
27	6V7742	NUT-FULL
2	6V8455	BOLT-HEX HEAD
4	7K1181	STRAP-CABLE
1	7X0909	BOLT
1	7X1547	SEAL-O-RING
42	7X7478	BOLT-LOCKING
5	8C3226	BOLT
14	8C8992	BOLT-HEX HEAD
17	8L2746	SEAL-O-RING
3	8L2779	SEAL-O-RING
1	8L2786	SEAL-O-RING
2	8P2053	RING-SEAL
3	8T0558	BOLT-HEX HEAD
4	8T0646	BOLT
4	8T1160	BOLT-SOCKET HD
14	8T4201	BOLT-HEX HEAD
4	8T5451	BOLT-HEX HEAD
12	9M1974	WASHER-HARD
1	9M9647	SEAL-O-RING
4	9X2125	BOLT-HEX HEAD
6	9X3402	SOCKET-CONNECTOR
4	9X8267	WASHER-HARD
1	0338248	CLIP-LOOP
1	0994691	BOLT-HEX HEAD
3	1003866	BOLT-HEX HEAD
1	1039603	GLASS-OIL LEVEL
1	1479502	CUP-ROLLER BRG
1	1479503	CONE-ROLLER BRG
1	1479505	CONE-ROLLER BRG
1	1527039	SEAL-O-RING
2	1552260	KIT-PLUG CONN
1	1629112	GROMMET-SPLIT
1	1727753	SEAL KIT
1	1924309	SEAL-O-RING
1	1967795	BRG AS. SP TR
8	1984776	WASHER-HARD
12	2678628	BOLT-HEX HEAD
1	2719167	HUB-PINION
8	2822628	BOLT-HEX HEAD
1	2877349	HOUSING
1	3172403	SEAL-O RING
1	3514089	GROMMET
1	3818975	SEAL-O-RING
1	4176922	SEAL AS
1	4387101	HARNESS AS
1	4950590	HOSE AS
32	4983750	BOLT-HEX HEAD
27	5045089	BOLT-GROUND BODY
1	5094091	GEAR SET - BEVEL
40	5158949	BOLT-12 POINT HD
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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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KENR8372 - Disassembly and Assembly Manual "Differential and Bevel Gear ? Assemble"
KENR8372 - Disassembly and Assembly Manual "Differential and Bevel Gear ? Disassemble"

Replace the 160-0020 or 279-2490 Bolts with 515-8949 Bolts when retaining the bevel gear and mating housing.

Perform the following tightening procedure for the bevel gear bolts.

Tighten all the bolts following the steps below.

Caption for Image 1:
Tighten bolts 1-8 in a cross pattern to 300 +/- 50 Nm.

Caption for Image 2:
Tighten bolts 1-40 in a circular pattern to 450 +/- 50 Nm.

Caption for Image 3:
Turn bolts 1-40 in a circular pattern an additional 30˚+/- 5˚

Replace the 149-2835 Ground Body Bolts with 504-5089 Ground Body Bolts. The 504-5089 Ground Body Bolts can be used on former 246-6762 Bevel Pinion with the proper inspection to ensure there is no interference issues. See M0081424 for Rework Instructions.

Perform the following tightening procedure for the pinion gear bolts.

Caption for Image 4:
Tighten nuts 1-4 in a cross pattern to 200 +/- 50 Nm.

Caption for Image 5:
Tighten nuts 1-27 in a circular pattern to 520 +/- 70 Nm.

Perform bevel gear chamfer - see rework instructions

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Image1

Image2

Image3

Image4

Image5

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%
0-9000 hrs, 0-18 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
9001-18000 hrs, 19-36 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%

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NOTE: This is a 95.0-hour job If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Use the following parts if/when not reusable: PINION HUB: 271-9167 BEVEL GEAR SET: 279-5131 HOUSING: 287-7349

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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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The chamfer measurement is 3 mm (0.118 inch) by 45 degrees

If chipping is still present around the threaded holes after a 3 mm (0.118 inch) chamfer, additional 2 mm (0.07874 inch) is allowed to be machined

If chipping is present after a total of 5 mm (0.197 inch), the bevel gear is not reusable