PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND TIGHTENING THE TORQUE CONVERTER TURBINE BOLTS ON CERTAIN 20R-6548 TRANSMISSIONS INSTALLED IN 735C, 740C EJ, AND 745C ARTICULATED TRUCKS Caterpillar

PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND TIGHTENING THE TORQUE CONVERTER TURBINE BOLTS ON CERTAIN 20R-6548 TRANSMISSIONS INSTALLED IN 735C, 740C EJ, AND 745C ARTICULATED TRUCKS

Usage:

TEBE5625-01

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04Jan2017

(Revised 28Feb2017)

U-10

A-10

D-10

O-10

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Priority Parts stock action needed	PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND TIGHTENING THE TORQUE CONVERTER TURBINE BOLTS ON CERTAIN 20R-6548 TRANSMISSIONS INSTALLED IN 735C, 740C EJ, AND 745C ARTICULATED TRUCKS
3101		PI32717

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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 must be administered as soon as possible. When reporting the repair, use "PI32717" 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 "PI32717" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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NOTE:

When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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 04Jan2017 Service Letter. Changes have been made to the Affected Product, Action Required, Service Claim Allowances, and Rework Procedure.

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COMPLETION DATE	TERMINATION DATE
31Jul2017	31Jan2018

PROBLEM

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The twenty 6V-4249 Bolts that connect the 335-0755 Coupling and 284-3602 Turbine to the 3914901/">391-4901 Hub in the torque converters on certain 20R-6548 Transmissions were tightened incorrectly at the factory. If the 20R-6548 Transmissions with serial numbers listed in the Rework Procedure is installed in a machine, it will need to be removed from the machine and the bolts will need to be inspected and tightened to the proper specification. The bolts can back out creating wear debris that can contaminate the transmission.

AFFECTED PRODUCT

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Model	Identification Number
735C	TFJ00167
740C EJ	TFN00165, 182-183, 185
745C	LFK00264, 457, 580 TFK00210, 291, 296, 383, 460, 489, 570, 649, 680, 755, 802, 945, 1028, 1072-1073, 1099, 1206, 1334

PARTS NEEDED

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Qty	Part Number	Description
4	0S1604	BOLT
1	1P3704	SEAL-RECTANGULAR
1	3K0360	SEAL-O-RING
1	4F7389	SEAL-O-RING
4	4J0522	SEAL-O-RING
1	4M6480	GASKET
4	6U0455	STRAP
4	6U0456	LASHING TIE 20
20	6V4249	BOLT-HEX HEAD
1	6V8398	SEAL-O-RING-ORFS
1	7M8485	SEAL-O-RING-STOR
1	8T2611	RING-RETAINING
1	9H0846	SEAL-O-RING
1	0619457	SEAL-O-RING
2	2287092	SEAL-O-RING-ORFS
2	2287093	SEAL-O-RING-ORFS
1	2385082	SEAL-O-RING-STOR
3	2385084	SEAL-O-RING-STOR
1	3375270	ELEMENT AS-XMSN
1	3914901	HUB-TURBINE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 5% 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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****Parts Stock ****

If a 20R-6548 transmission with a serial number listed in Image 1 is found in parts stock, follow Method 1 from the attached Rework Procedure to correct the bolt torque before installation.

If a 20R-6548 transmission with a serial number listed in Image 1 is now in service in an Articulated Truck, document the machine serial number that the transmission was installed, a transmission serial number from Image 1, and provide the information to your Dealer Technical Communicator (TC). Request the Dealer TC to submit the information to CPI number 382312 through CPI Feedback within the Service Information Management System (SIMSi) to have the Affected Product updated with an Articulated Truck that is now equipped with a transmission listed in Image 1.

Image1

****Affected Product****

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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****Parts Stock****

Submit one claim for each transmission reworked in dealer parts stock. 3 hours are allowed to rework a transmission in part stock. One 8T-2611 is allowed for a transmission reworked in part stock.

****Affected Product****

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Caterpillar		Dealer Suggested		Customer Suggested
Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
100%	100%	0%	0%	0%	0%

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NOTE: This is a 1.0-hour job
Note: If the reman transmission from the list is present and has not been updated, then additional 65.0 hours labor is allowed for removal and rework of the transmission. Note: If the reman transmission was serviced per the program, then the transmission serial number must be included in the claim.

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PARTS DISPOSITION

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****Parts Stock****

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

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****Affected Product****

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

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Rework Procedure

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Park the machine on a hard, level surface and, referring to the Operation and Maintenance Manual, apply the parking brake, stop the engine, raise the hood and turn the battery disconnect switch to the ?off? position.

The list of affected transmission serial numbers is listed in Image1.1.1 along with the machine the transmission is installed in. Before proceeding, verify if the serial number of the 20R-6548 transmission installed in the truck is on the list. The serial number on the tag could have an extra digit such as "0" or "2" after the MJ8 prefix. Please use the last four numbers and letter of the serial number for verification. (Example: MJ82169A could be MJ802169A on the tag.) If the serial number of the transmission is not in the table, no further action is needed. If the serial number is listed, the transmission will need to be removed to have the torque converter bolts shown in Image1.1.3 inspected and tightened to specification.

Create a DSN - Product Health Service Request (SR) with Dealer expectation = Product Inquiry / Informational to report the transmission serial number and the repairs. Close the request at the dealership without submitting to Caterpillar.

Image1.1.1

Image1.1.2

TRANSMISSION REMOVAL:

Prior to rework, refer to UENR4227, Disassembly and Assembly, 735C, 740C EJECTOR and 745C Articulated Trucks Power Train, "System Pressure - Release".

Drain the oil from the transmission system which will include the torque converter, transmission and output transfer gear. Refer to SEBU9060, 735C and 745C Articulated Trucks, Operations and Maintenance and SEBU9061, 740C Ejector, "Torque Converter, Transmission, and Transfer Gear Oil - Change".

To remove the transmission, refer to UENR4227, Disassembly and Assembly, 735C, 740C EJECTOR and 745C Articulated Trucks Power Train, "Transmission - Remove and Install".

DISASSEMBLY AND ASSEMBLY PROCEDURES:

The link below contains a video with additional information available for disassembly and assembly of the transmission.

Caterpillar Channel 1 Video: "CX38 Disassembly and Assembly"
Media Number: CATU0825
Channel 1 URL (direct link to video): https://channel1.videonitch.com/LearningPrograms/Pass/3383

The bolts can be inspected and torqued by removing the torque converter from the transmission (Method 1) or by just removing the clutch housing from the torque converter while still installed in the transmission (Method 2). Method 2 is only recommended if no additional damage is suspected as the torque converter would have to be completely removed if there is additional damage from the bolts coming loose.

METHOD 1:
To remove and install the torque converter, refer to UENR4227, Disassembly and Assembly, 735C, 740C EJECTOR and 745C Articulated Trucks Power Train.

For disassembly and assembly of the torque convertor, refer to UENR4227, Disassembly and Assembly, 735C, 740C EJECTOR and 745C Articulated Trucks Power Train.

If failure of the 6V-4249 bolts is not evident, inspect bolts to see if any are loose. If not, tighten the bolts to a specified torque of 60 +/- 7 N.m and reassemble the torque converter.

If bolts are loose, inspect 3914901/">391-4901 Turbine Hub threads and replace with new hub as needed. Inspect for any resultant damage. Replace all twenty 6V-4249 Bolts and tighten to a specified torque of 60 +/- 7 N.m. Include the condition of the loose bolts and the transmission serial number in the "Request Detail" section of the Product Inquiry / Informational DSN SR and close the SR at the dealership.

METHOD 2:
The 6V-4249 Bolts can be inspected without removing the torque converter completely and following only certain steps from UENR4227, Disassembly and Assembly, 735C, 740C EJECTOR and 745C Articulated Trucks Power Train.

From the Torque Converter ? Remove section, follow Steps 1 and 2.

From the Torque Converter ? Disassemble section, follow Step 1. However, you will not need to remove the D-ring seal.

From the Torque Converter ? Assemble section, follow Step 12 for tightening the bolts and Steps 14 through 16. For Step 14, inspect the inner and outer seal ring before installing them.

From the Torque Converter ? Install section, follow Steps 5 and 6.

If failure of the 6V-4249 bolts is not evident, inspect bolts to see if any are loose. If not, tighten the bolts to a specified torque of 60 +/- 7 N.m and reassemble the torque converter.

If bolts are loose, inspect 3914901/">391-4901 Turbine Hub threads and replace with new hub as needed. Inspect for any resultant damage. Replace all twenty 6V-4249 Bolts and tighten to a specified torque of 60 +/- 7 N.m. Include the condition of the loose bolts and the transmission serial number in the "Request Detail" section of the Product Inquiry / Informational DSN SR and close the SR at the dealership.

TRANSMISSION INSTALLATION:

Before installation of the transmission, the transmission hydraulic lines, cooler, and output transfer gear must be inspected for contamination.

To install the transmission refer to UENR4227, 735C, 740C EJECTOR and 745C Articulated Trucks Power Train, "Transmission Remove and Install".

When filing a claim for the repair, include the transmission serial number in the claim story.