2000/06/19 Caterpillar

Correction to Service Magazine, 9EP3441, 31 October 1999 , "New Thrust Washer Improves Service Life of Differential Group" {3258}

Usage:

AD40 1YZ

Load Haul Dump (LHD): R2900 (PIN: BAR; 5TW1-UP)
Underground Articulated Truck (UAT): AD40 (PIN: 1YZ) AE40 (PIN: 1ZZ)

Service Magazine 9EP3441, 31 October 1999, "New Thrust Washer Improves Service Life of Differential Group". This article includes incorrect information. Disregard this article. Refer to the article that follows.

Reference: Disassembly and Assembly, 6DE2110, "Elphinstone AD40 & AE40 Articulated Truck Power Train", "Disassemble, Assemble, Differential and Bevel Gear"

Reference: Disassembly and Assembly, 6DE6651, "AD40 & AE40 Series II Truck Power Train", "Disassemble, Assemble, Differential and Bevel Gear"

Reference: Disassembly and Assembly, 9EL3671, "R2900 L.H.D. Power Train", "Disassemble, Assemble, Differential and Bevel Gear"

Reference: Specifications, 6DE2098, "Elphinstone AD40 & AE40 Articulated Truck Power Train", "Differential and Bevel Gear"

Reference: Specifications, 6DE6648, "AD40 & AE40 Series II Truck Power Train", "Differential and Bevel Gear"

Reference: Specifications, 9EL3668, "R2900 L.H.D. Power Train", "Differential and Bevel Gear (Front and Rear)"

Description of Change: An improved thrust washer for the differential side gear is available.

Adaptable To: The new 172-4700 Thrust Washer is effective with the following machines: AD/AE40-165 & Up and 5TW318-UP.

Refer to the procedure that is shown below. The 172-4700 Thrust Washer is adaptable to the following machines: AD/AE40-101 to 164, R2900-101 to 170 and 5TW1-317.

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Table 1
Required Parts ⁽¹⁾
Qty	Part Number	Description
2	172-4700	Thrust Washer
8	127-1960	Screw

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^( 1 )

The parts are required for each differential.

Procedure

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Illustration 1	g00716340
(1) Case Assembly (2) Spider Assembly (3) Washer (4) Pinion Gear (5) Gear (6) Thrust Washer (7) Bearing Sleeve (8) Washer (9) Washer (10) Bolt

Remove the differential case assembly (1) from the differential and bevel gear. Refer to Illustration 1.

Remove the bolts (10) and the washers (9) from the case assembly (1). Refer to Illustration 1.

Refer to Illustration 1. Remove the following items from the case assembly (1) : spider assembly (2), washers (3), pinion gears (4), gears (5), thrust washers (6), bearing sleeves (7) and washers (8) .

Note: Thrust washer (6) and washer (8) will be replaced by the 172-4700 Thrust Washer .

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Illustration 2	g00716488
(1) Case Assembly (11) Screw (12) Thrust Washer

Drill four holes. The four holes need to be equally spaced 90° from each other in both halves of case assembly (1). The four holes need to be drilled to a diameter of 5.2 mm (0.20 inch) and a depth of 20.0 mm (0.79 inch).
Note: The 172-4700 Thrust Washer (12) may be used as a template. The template can be used in order to mark the position of the new drill holes.

Counterbore the eight holes to a diameter of 9.5 ± 0.5 mm (0.37 ± 0.020 inch) and a depth of 4.8 ± 0.5 mm (0.19 ± 0.02 inch).

Tap each hole M6 X 1 - 6H thread to a depth of 15.0 mm (0.59 inch).

Clean all of the contact surfaces with a solvent cleaner.

Apply a thin layer of 4C-9507 Retaining Compound or an equivalent retaining compound to the face of both differential cases. Apply the compound to the contact position of the differential case and the new thrust washer.

Apply a sufficient amount of 4C-9506 Retaining Compound or a similar retaining compound to each screw in order to lock the threads and bond the screw heads to the washer. Refer to Illustration 2.

Tighten each screw to a torque value of 12 ± 3 N·m (8.8 ± 2.2 lb ft).
Note: Do not exceed the torque value of the screws.

Clean off excess retaining compound.

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Illustration 3	g00716489
(1) Case Assembly (2) Spider Assembly (3) Washer (4) Pinion Gears (5) Gears (7) Bearing Sleeve (9) Washer (10) Bolt (11) Screw (12) Thrust Washer

Refer to Illustration 3. Install the following items to the case assembly (1) : spider assembly (2), washers (3), pinion gears (4), gears (5), thrust washers (6), bearing sleeves (7) and washers (8) .