THE DIFFERENTIAL RETAINING RINGS MAY FAIL ON CERTAIN 797B AND 797F OFF-HIGHWAY TRUCKS Caterpillar

THE DIFFERENTIAL RETAINING RINGS MAY FAIL ON CERTAIN 797B AND 797F OFF-HIGHWAY TRUCKS

Usage:

TEBE5259-04

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27Sep2016

(Revised 10Sep2018)

N030
N061
N184
N18C
N18D

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After Failure Only (Limited distribution)	THE DIFFERENTIAL RETAINING RINGS MAY FAIL ON CERTAIN 797B AND 797F OFF-HIGHWAY TRUCKS
3258 3281 3256		PS53306

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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 "PS53306" 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 27Sep2016 (Revised 04Dec2017) Service Letter. Changes have been made to the Termination Date.

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TERMINATION DATE

30Sep2019

PROBLEM

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The 6J-7855 Snap Rings, in the 279-5128 Differential Group of certain 797B and 797F Off-Highway Trucks, have experienced failures that lead to cracking, fracturing, or being incorrectly seated inside the groove.

AFFECTED PRODUCT

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Model	Identification Number
797B	JSM00123, 127-128, 130-131, 135-136, 139-142, 144-149, 151-164, 191-194, 206-212, 216-217, 219, 221-228, 236-238, 244, 256, 261, 265-267, 276-279, 296, 298, 302-303, 308, 311-317, 320-332, 338-353, 364-365, 369-382, 386-389, 393-395, 398-402, 404-409, 412-413, 415, 418, 422, 424, 426, 430, 432, 434-439, 446, 449-451, 453, 456-457, 461-462, 472, 476-488
797F	LAJ00142-00144, 189, 200-203, 227-228, 251-255, 262, 264, 266-269, 276, 283, 285, 287, 292-293, 295-296, 303, 308, 311-314, 316-322, 327-328, 341, 343-344, 350-351, 365, 372-373, 445-446, 458-461, 464-466, 468, 476-477, 483, 491-494, 507, 509-512, 523-525, 554-561, 569-571, 573-584, 596

PARTS NEEDED

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Qty	Part Number	Description
4	1A5350	CLIP
1	2D1692	SEAL-O-RING
1	2S8439	SEAL-O-RING
2	3G1229	SHIM
1	3G1230	SHIM
1	3G1231	SHIM
1	3H2617	PIN-SPRING
1	3S1349	WASHER-HARD
5	4B9302	CLIP-LOOP
4	4D7536	LOCK-NUT
2	4J5977	NUT-FULL
1	4P7428	CLIP-LADDER
1	4P7429	CLIP-LADDER
2	4P7581	CLIP-LADDER
1	5F6222	SEAL-O-RING
1	5K9239	ADAPTER-STR
1	5K9241	ELBOW
1	5P5846	SEAL-O-RING
40	5P6604	WASHER-HARD
1	5P6718	SEAL-O-RING
1	5P7701	SEAL-O-RING
1	5P7815	SEAL-O-RING
81	5P8245	WASHER-HARD
1	6A5591	BOLT
2	6C3218	BOLT
1	6J1080	GROMMET
4	6K1984	DOWEL
1	6V0460	CUP-RLR BRG
2	6V1819	BOLT
1	6V3298	PLUG-MAGNETIC
14	6V3668	BOLT
32	6V3669	BOLT
1	6V3830	SEAL-O-RING
4	6V4248	BOLT
9	6V4589	SEAL-O-RING
12	6V5219	BOLT-HEX HEAD
1	6V5266	SEAL-O-RING
3	6V5684	BOLT-HEX HEAD
1	6V5759	SEAL-O RING
22	6V5839	WASHER-HARD
14	6V6317	BOLT
3	6V7673	BOLT-HEX HEAD
27	6V7742	NUT-FULL
1	6V8197	BOLT
2	6V8212	BOLT-HEX HEAD
28	6V8675	BOLT
4	7K1181	STRAP-CABLE
1	7M8485	SEAL-O-RING-STOR
1	7X0909	BOLT
22	7X7478	BOLT-LOCKING
5	8C3226	BOLT
1	8D4771	SEAL-O-RING
1	8E6328	RING-SEALING
14	8L2746	SEAL-O-RING
3	8L2779	SEAL-O-RING
1	8L2786	SEAL-O-RING
2	8P2053	RING-SEAL
4	8T0646	BOLT
4	8T1160	BOLT-SOCKET HD
32	8T3282	WASHER-HARD
6	8T4121	WASHER-HARD
3	8T4136	BOLT-HEX HEAD
1	8T4137	BOLT-HEX HEAD
1	8T4139	BOLT-HEX HEAD
1	8T4185	BOLT-HEX HEAD
1	8T4195	BOLT-HEX HEAD
1	8T4223	WASHER-HARD
4	8T5451	BOLT-HEX HEAD
8	8T7547	BOLT-HEX HEAD
12	9M1974	WASHER-HARD
1	9M9647	SEAL-O-RING
4	9X8267	WASHER-HARD
12	9X8268	WASHER
1	0336033	SEAL-O-RING
1	0919035	SPACER-HARD
1	1061242	SPACER
2	1160118	CLIP
1	1261278	PLUG-ORIFICE
1	1305300	CLIP
1	1305301	CLIP
1	1428927	BODY AS-GAGE
1	1527039	SEAL-O-RING
1	1550797	TUBE AS.
1	1550803	SEAL-FACE&RADIAL
4	1564594	BEARING ASSEMBLY
1	1629112	GROMMET-SPLIT
1	1652319	SHIM
1	1691041	PLUG-PIPE
1	1726104	SCREEN AS.
1	1727753	SEAL KIT
4	1839511	GEAR-SPIDER
8	1984776	WASHER-HARD
12	2026473	BOLT-HEX HEAD
1	2041557	SHIM
10	2042281	STRAP-CABLE
8	2048000	MOUNT-TIE WRAP
2	2307732	MOUNT-TIE WRAP
4	2795126	PIN (If/AsNecessary)
1	2905792	SENSOR GP-SPD -A
2	3097670	WASHER - DIFF
4	3347862	PIN (If/AsNecessary)
1	3514089	GROMMET
1	3818975	SEAL-O-RING
1	4176922	SEAL AS
1	4387101	HARNESS AS
2	4785300	SENSOR GP-SPD -A
1	4950590	HOSE AS
4	5327617	RING-RETAINING
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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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Refer to the Service Manual if/as necessary.

Refer to service manual for mag plug and screen inspections if/as necessary.

Inspect the retaining ring groove at PCR or when component has been removed for service for presence of debris or damage. Remove any debris found in the groove with a brush or rag. Do not alter the retaining ring groove geometry. If the edges or corners of the groove have significant damage or have worn excessively, replace the housing.

Following pin installation, make sure the pin is fully seated and retaining ring groove fully exposed. Once the retaining ring is installed, check for full expansion into groove by measuring the distance between the two open ends. The distance should be minimum of 11 mm (0.4 inch). Distance may be measured with caliper or a dealer fabricated gauge block described in the Rework Procedure. If retaining ring is not fully expanded, make sure that pin is fully seated and groove is free of debris or damage.

Refer to M0086897 - Salvage of Differential Housing Assembly Used on Certain 797F Off-Highway Trucks to determine if 279-5126 Pin or 334-7862 Pin should be used.

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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%
0-9000 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 90.0-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.
The 90 total hours of labor is recommended as 36 hours for Removal and Install and 54 hours for Disassembly and Assembly. Refer to M0086897 - Salvage of Differential Housing Assembly Used on Certain 797F Off-Highway Trucks to determine if 279-5126 Pin or 334-7862 Pin should be used. Only 4 pins are allowed per claim.

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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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Machine block (B) to a dimension of 11.0 x 11.0 mm square.
Place block between the ears of each retaining ring indicated by an arrow as shown in Image 1.1.1. Use block (B) as go/no go gauge. Drill and tap a small hole on one end of the block to fit desired handle. The gauge block should fit between open ends of snap ring when fully expanded into groove.