Salvage of Center Bearing in Torque Converter Input Housing {3101, 3127} Caterpillar

Articulated Truck

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730 (S/N: 3F31-UP)

730 EJECTOR (S/N: 3F41-UP; 3T41-UP)

735 (S/N: 3F51-UP; 3T51-UP)

740 GC (S/N: 3F81-UP; 3T81-UP)

Integrated Toolcarrier

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Landfill Compactor

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Load Haul Dump

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Off-Highway Truck/Tractor

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785G (S/N: RTL1-UP)

On-Highway Transmission

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Petroleum Transmission

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Pipelayer

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Soil Compactor

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Track-Type Loader

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Track-Type Tractor

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Transmission

TH55FT-E70 (S/N: PCJ1-UP)

Underground Articulated Truck

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Wheel Dozer

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Wheel Loader

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Wheel Skidder

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Wheel Tractor-Scraper

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Introduction

Table 1

Revision	Summary of Changes in SEBF8118
20	Updated Effectivity Added new serial number prefixes for New Product Introduction (NPI), Added References 2, Added Columns: Part Numbers, Part Number Descriptions, Casting Number Descriptions414, Added Tables1516, Inserted contents from SEBF2118Reuse and Salvage Guidelines, "Thermal Spray Procedures for Torque Converter Input Housing". Added Illustrations 2324 Updated References Table 2, Tooling Table 3, and boilerplate information.
19	Updated References Table, Tooling Table 3, and added "Measurement Techniques" section.
18	Added new serial number prefixes for New Product Introduction (NPI). Updated copyright date to 2018. Removed Repair Process Engineering old point of contacts. Added new Repair Process Engineering point of contact.
17	Updated 1 part number.
16	Added 5 part numbers.

© 2019 Caterpillar All Rights Reserved. This guideline is for the use of Cat dealers only. Unauthorized use of this document or the proprietary processes therein without permission may be violation of intellectual property law.

Information contained in this document is considered Caterpillar: Confidential Yellow.

This Reuse and Salvage Guideline contains the necessary information to allow a dealer to establish a parts reusability program. Reuse and salvage information enables Caterpillar dealers and customers to benefit from cost reductions. Every effort has been made to provide the most current information that is known to Caterpillar. Continuing improvement and advancement of product design might have caused changes to your product which are not included in this publication. This Reuse and Salvage Guideline must be used with the latest technical information that is available from Caterpillar.

For technical questions when using this document, work with your Dealer Technical Communicator (TC).

To report suspected errors, inaccuracies, or suggestions regarding the document, submit a form for feedback in the Service Information System (SIS Web) Interface.

Canceled Part Numbers and Replaced Part Numbers

This document may include canceled part numbers and replaced part numbers. Use the Numerical Part Record (NPR) on the Service Information System Website (SIS Web) for information about canceled part numbers and replaced part numbers. NPR will provide the current part numbers for replaced parts.

Important Safety Information

Illustration 1	g02139237

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools to perform these functions properly. Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. If a tool, a procedure, a work method, or operating technique that is not recommended by Caterpillar is used, ensure that it is safe for you and for other people to use. Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or the repair procedures that are used.

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Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the “Safety Alert Symbol” which is followed by a “Signal Word” such as “DANGER”, “WARNING” or “CAUTION”. Refer to Illustration 2 for an example of a “WARNING” Safety Alert Symbol.

Illustration 2	g00008666

This safety alert symbol means:

Pay Attention!

Become Alert!

Your safety is Involved.

The message that appears under the safety alert symbol explains the hazard.

Operations that may cause product damage are identified by "NOTICE" labels on the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The safety information in this document and the safety information on the machine are not all inclusive. Determine that the tools, procedures, work methods, and operating techniques are safe. Determine that the operation, lubrication, maintenance, and repair procedures will not damage the machine. Also, determine that the operation, lubrication, maintenance, and repair procedures will not make the machine unsafe.

The information, the specifications, and the illustrations that exist in this guideline are based on information which was available at the time of publication. The specifications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete, most current information before you start any job. Caterpillar dealers can supply the most current information.

Summary

Thermal spraying is a group of processes. Fine molten metallic materials are deposited onto a prepared surface. These materials are then honed and finished to specifications that match the original specifications. This instruction manual involves the necessary dimensions for using thermal spraying for the salvage of center bearings in input housings of the torque converter.

Illustration 3	g01470012
Wear area on the input housing for the torque converter. (A) Wear Area

References

Table 2

References
Media Number	Publication Type & Title
Channel1	"Why Reuse and Salvage Parts"
	https://channel1.mediaspace.kaltura.com/media/Why+Reuse+and+Salvage+Parts/0_ae9rhu2z
Oerlikon Metco Inc.	https: //www.oerlikon.com/metco
PERJ1017	Reuse and Salvage Guidelines "Dealer Service Tools Catalog"
SEBF8060	Reuse and Salvage Guidelines "Repair of Transmission, Torque Converter and Torque Divider Shafts"
SEBF8187	Reuse and Salvage Guidelines "Standardized Parts marking Procedures"
SEBF9240	Reuse and Salvage Guidelines "Fundamentals of Flame Spray for Reconditioning Components" (1)

(1)	Only Cat dealers may utilize applications for Thermal Spray. The processes must be carried out within the facilities of the dealership. The dealership must maintain a clean environment and always use the correct equipment for all processes in each Thermal Spray Application.

Service Advisories, Service Letters, and Technical Service Bulletins

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NOTICE
The most recent Service Advisories, Service Letters, and Technical Service Bulletins that are related to this component should be reviewed before beginning work. Often Service Advisories, Service Letters, and Technical Service Bulletins contain upgrades in repair procedures, parts, and safety information which pertain to the components being repaired.

Tooling and Equipment

Note: The Tooling and Equipment in Table 3 is not an all inclusive list of Tooling required to perform every task within this document. Tooling needs may vary for the scope of work to be performed for each specific rebuild.

Table 3

Required Tooling and Equipment
Part Number	Description	Designation
(1)	Personal Protective Equipment (PPE)	Personal Protection
— (2)	Clevis/ Shackle	Component Repositioning and Movement
— (2)	Lifting Eye Assemblies	Component Repositioning and Movement
— (2)	Tool (Cribbing)	Component Repositioning and Movement
—	Suitable Lifting Device	Component Repositioning and Movement
1P-3537	Dial Bore Gauge Group	Internal Measurement Checks
385-9422	Tools (Micrometer) Internal (2 - 24 inch)	Internal Measurement Checks
386-3364	Tool (Ruler) 1,000.0 mm (39.37 inch)	Measurement Checks
431-4150	Micrometers External 0 - 25 mm (0 - 1 inch)	External Measurement Checks
473-8688 or 473-8689	Instrument Group Micrometer, Inside 2.00 - 12.00 inch	Internal Measurement Checks
	Instrument Group Micrometer, Inside 50 - 300 mm
473-8690	Instrument Group Micrometer, Outside 0.00 - 4.00 inch	External Measurement Checks
473-8691	Instrument Group Micrometer, Outside 2.00 - 6.00 inch	External Measurement Checks
473-8692	Instrument Group Micrometer, Outside - Digital 152.4 - 304.8 mm (6.00 - 12.00 inch)	External Measurement Checks
474-3709 or 474-3710	Instrument Group Micrometer, Inside (8.00 - 32.00 inch)	Internal Measurement Checks
	Instrument Group Micrometer, Inside 200 - 800 mm
1U-6832	Abrasive Disc	Surface Preparation / De-burring
1U-6846	Abrasive Disc	Surface Preparation / De-burring
1U-5516	Disc (Coarse)	Surface Preparation / De-burring
1U-5518	Threaded Shaft	Surface Preparation / De-burring
1U-5519	Holder (Disc Pad)	Surface Preparation / De-burring
4C-8521	Wheel Adapter	Surface Preparation / De-burring
4C-8515	Grinding Wheel (F-Grade) (2 x 1 inch) (120 Grit)	Surface Preparation / De-burring
4C-8519	Abrasive Flap Wheel (3 x 1 inch) (180 Grit)	Surface Preparation / De-burring
254-5342	Flap Disc	Surface Preparation / De-burring
254-5307	Pad	Surface Preparation / De-burring
254-5309	Pad	Surface Preparation / De-burring
222-3076	Die Grinder (Right Angle)	Surface Preparation / De-burring
222-3071	Portable Angle Grinder Group	Surface Preparation / De-burring
222-3074	Wheel Grinder Group	Surface Preparation / De-burring
222-3077	Die Grinder	Surface Preparation / De-burring
254-5319	Brush 76.2 x 50.8 mm (3.00 x 2.00 inch)	Surface Preparation / De-burring
9U-7377 (3)	Metal Marking Pen	Parts Marking
223-1154	Metal Marking Pen (AIR)	Parts Marking
6V-2010	Polishing Stone	Gear Polishing
1U-9918	Brush	General Cleaning
1U-5512	Abrasive Material (Roll)	General Cleaning
8T-7765	Surface Reconditioning Pad (180 Grit)	General Cleaning
162-5791(4)	Towel	General Cleaning

(1)	Refer to PERJ1017Special Publication, "Dealer Service Tools Catalog" for Personal Protective Equipment (PPE) part numbers suitable by geographic location and local safety standards.
(2)	Refer to Special Publication, PERJ1017, "Dealer Service Tools Catalog" for suitable tooling.
(3)	Available in the United States only.
(4)	Refer to Flame Spray Equipment and Procedure and Flame Spray Process Tables 18 19

Preparation Recommendations

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Personal injury can result when using cleaner solvents. To help prevent personal injury, follow the instructions and warnings on the cleaner solvent container before using.

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Personal injury can result from air pressure. Personal injury can result without following proper procedure. When using pressure air, wear a protective face shield and protective clothing. Maximum air pressure at the nozzle must be less than 205 kPa (30 psi) for cleaning purposes.

Illustration 4	g03794147
Typical burr removal Tooling. (A) Die Grinder, Right Angle (B) Wheel Grinder, Group (C) Conditioning Discs, Disc pad Holder, and Threaded Shaft (D) Flapper Wheel

• Before you inspect a part, clean the part thoroughly to ensure that all components are free from rust, oil, burrs, and debris prior to inspection. A surface irregularity can hide the indication of an unacceptable defect

• Use a proper lifting device to provide safety to the operator. Also, use a proper lifting device to prevent damage to the part when you lift the part.

• During cleaning, do not damage machined surfaces.

• Use pressurized air to dry parts.

• Inspect all flange mating surfaces for fretting. Ensure that flange mating surfaces are true and free from raised material resulting from rust, nicks, and dents.

• Use appropriate thread taps to chase all threaded holes.

Standardized Parts Marking Procedure

Reference: SEBF8187Reuse and Salvage Guidelines, "Standardized Parts Marking Procedures".

The code is a Cat standard and is used to record the history of a component. The code will identify the number of rebuilds and hours at the time of each rebuild. This information is important and should be considered for any decision to reuse a component.

Ensure that the mark is not covered by a mating part.

The procedure for marking components is a Cat standard. This code is helpful when the machine is sold into a different territory after the first rebuild. During an overhaul, the previous code of a part should never be removed.

Example 1

Illustration 5	g03748255
Typical Example

Illustration 5 shows code (1-15). The first number (1) indicates that the component had been rebuilt once. The second number (15) indicates that there were 15,000 hours on the component at the time of rebuild.

Example 2

Illustration 6	g03748362
Typical Example

Illustration 6 shows code (1-12) and code (2-10). Code (2-10) represents the information from the second rebuild. The first number (2) indicates that the component had been rebuilt twice. The second number (10) indicates that 10,000 hours accumulated on the component between the first and second rebuild.

Note: Add the first and second rebuild hours to obtain the total number of hours for the component in Illustration 6. In this example, the component has a total of 22,000 hours.

Measurement Techniques

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NOTICE
Precise measurements shall be made when the component and measurement equipment are at 20° C (68° F). Measurements shall be made after both the component and measurement equipment have had sufficient time to soak at 20° C (68° F). Ensuring that both the surface and core of the material is at the same temperature will increase the accuracy of the measurement taken.

Measurement Tooling Calibration

Outside Micrometers

Illustration 7	g06208395
Typical example of calibrating outside micrometer (A). (A) Outside Micrometer

Measurement Tooling include precision inside and outside diameter micrometers capable of measuring four decimal places in inches or three decimal places in millimeters. Measurement Tooling should be calibrated using gauge blocks certified to a national standard such as the National Institute of Standards and Technology (NIST).

Inside Micrometer

Illustration 8	g06208411
Typical example of calibrating inside micrometer (B). (B) Inside Micrometer

Bore Diameters

Illustration 9	g06340657
Typical example of measuring bore Inside Dimension (ID) of a component. (A) Indicates the diameter of the bore. (B) Indicates the overall thickness of the material.

Note: Measurements taken on the edge of a bore may not give an accurate measurement.

Take measurements at locations (A1), (A2), and (A3).

Then take measurements at locations (A4), (A5), and (A6).

To ensure adequate life of the components, this document contains precise tolerances for measurements taken on various features. Ensure that several sample measurements are taken at different locations on the same feature. Measure diameters of internal bores in six places to identify tapered and or oval conditions. Refer to Illustration 9.

Illustration 10	g06001444
Typical example of measuring a large bore.

Illustration 11	g03772954
Typical example of measuring a small bore.

Dimensional Information

Illustration 12	g01470493
(B) Diameter (C) Face (D) Pilot Bore Location

Table 4

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 12
Part Number	Description	Casting Number	Material Type	Diameter (B)
1T-0228	Housing	1T-0228	Ductile	Ø 169.99 ± 0.013 mm (6.69 ± 0.0005 inch)
295-4685 1T-2080	Housing	1T-0437 1T-2080	Gray Cast Iron	Ø 119.98 ± 0.013 mm (4.72 ± 0.0005 inch)
516-7986	Housing	1T-0669	Ductile	Ø 132.56 ± 0.025 mm (5.22 ± 0.001 inch)
1T-0799	Rotation Housing Assembly	1T-0778	Nodular Iron Casting	Ø 80.96 ± 0.013 mm (3.19 ± 0.0005 inch)
1T-0799	Rotation Housing Assembly	1T-0798	Ductile	Ø 80.96 ± 0.013 mm (3.19 ± 0.0005 inch)
—	Rotation Housing	1T-0829	Aluminum Casting	Ø 132.56 ± 0.025 mm (5.22 ± 0.001 inch)
434-3303	Housing	1T-0849	Ductile	Ø 119.99 ± 0.013 mm (4.72 ± 0.0005 inch)
2P-5861	Rotation Housing Assembly	2P-4394	Ductile	Ø 80.962 ± 0.013 mm (3.1875 ± 0.0005 inch)
2P-5693	Housing	2P-5693	Ductile	Ø 133.35 ± 0.03 mm (5.25 ± 0.0012 inch)
8P-8780	Housing	8P-8780	Ductile	Ø 169.987 ± 0.013 mm (6.6924 ± 0.0005 inch)
235-2418	Housing Assembly	235-2417	Ductile Iron Casting	Ø 80.962 ± 0.013 mm (3.1875 ± 0.0005 inch)
364-5467	Clutch Housing Assembly	288-2671 288-2673 288-2669 364-5466	Ductile	Ø 80.962 ± 0.013 mm (3.1875 ± 0.0005 inch)
346-5011	Rotating Housing	346-5011	Ductile	Ø 119.99 ± 0.013 mm (4.724 ± 0.0005 inch)
384-1847	Clutch Housing Assembly	364-5468	Ductile	Ø 80.962 ± 0.013 mm (3.1875 ± 0.0005 inch)
384-1847	Clutch Housing Assembly	384-1845	Ductile	Ø 80.962 ± 0.013 mm (3.1875 ± 0.0005 inch)
391-4900	Clutch Housing Assembly	391-4899	Ductile Iron Casting	Ø 80.962 ± 0.013 mm (3.1875 ± 0.0005 inch)

Illustration 13	g01470700
(B) Diameter (C) Face (D) Pilot Bore Location (E) Diameter (F) Depth

Table 5

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 13
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (E)	Depth (F)
1T-1927	Housing	1T-0024 1T-1828	Ductile	Ø 98.57 ± 0.013 mm (3.88 ± 0.0005 inch)	Ø 89.99 ± 0.013 mm (3.54 ± 0.0005 inch)	8.70 ± 0.040 mm (0.34 ± 0.0016 inch)
1T-0085	Housing	1T-0085	Gray Cast Iron	Ø 80.00 ± 0.013 mm (3.15 ± 0.0005 inch)	—	18.06 ± 0.050 mm (0.71 ± 0.0020 inch)
1T-1029	Housing	1T-1029	Ductile	Ø 99.99 ± 0.013 mm (3.94 ± 0.0005 inch)	Ø 85.75 ± 0.025 mm (3.38 ± 0.0010 inch)	25.07 ± 0.050 mm (0.99 ± 0.0020 inch)
1T-1496	Housing Assembly	1T-1497	Ductile	Ø 129.99 ± 0.013 mm (5.12 ± 0.0005 inch)	Ø 101.63 ± 0.03 mm (4.00 ± 0.0012 inch)	25.07 ± 0.08 mm (0.99 ± 0.0031 inch)
3T-9138	Clutch Housing	3T-9138	Ductile	Ø 129.99 ± 0.013 mm (5.12 ± 0.0005 inch)	Ø 101.63 ± 0.050 mm (4.00 ± 0.0020 inch)	27.00 ± 0.050 mm (1.06 ± 0.0020 inch)
6Y-4859	Housing	6Y-4859	Gray Cast Iron	Ø 129.97 ± 0.03 mm (5.12 ± 0.0012 inch)	Ø 120.00 ± 0.50 mm (4.72 ± 0.02 inch)	37.10 ± 0.08 mm (1.46 ± 0.0032 inch)
—	Housing	7T-1840	Ductile	Ø 215.015 ± 0.015 mm (8.47 ± 0.0006 inch)	Ø 212.92 ± 0.050 mm (8.38 ± 0.0020 inch)	116.00 ± 0.050 mm (4.57 ± 0.0020 inch)
144-0812	Rotating Housing	144-0812	Ductile Iron Casting	Ø 129.98 ± 0.030 mm (5.12 ± 0.0012 inch)	Ø 120.00 ± 0.500 mm (4.72 ± 0.0197 inch)	54.00 ± 0.130 mm (2.13 ± 0.0051 inch)
197-4580	Housing	197-4580	Ductile	Ø 99.99 ± 0.013 mm (3.94 ± 0.00051 inch)	Ø 85.75 ± 0.02 mm (3.38 ± 0.00079 inch)	25.07 ± 0.05 mm (0.99 ± 0.002 inch)

Illustration 14	g01476535
(B) Diameter (C) Face (D) Pilot Bore Location (F) Depth

Table 6

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 14
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (E)	Depth (F)
1T-1009	Rotation Housing Assembly	1T-1008	Ductile	Ø 65.09 ± 0.013 mm (2.56 ± 0.0005 inch)	—	26.92 ± 0.250 mm (1.06 ± 0.0098 inch)
1T-1850	Housing Assembly	1T-1638 1T-1851	Ductile Iron Casting	Ø 65.09 ± 0.013 mm (2.56 ± 0.0005 inch)	—	26.92 ± 0.250 mm (1.06 ± 0.0098 inch)
1T-1940	Housing Assembly	1T-1941	Gray Cast Iron	Ø 65.09 ± 0.013 mm (2.56 ± 0.0005 inch)	—	26.92 ± 0.250 mm (1.06 ± 0.0098 inch)
6Y-0799	Clutch Housing Assembly	6Y-0800	Ductile Iron Casting	Ø 80.96 ± 0.013 mm (3.19 ± 0.0005 inch)	—	44.50 ± 0.130 mm (1.75 ± 0.0051 inch)
6Y-4859	Housing	6Y-4859	Gray Cast Iron	Ø 129.97 ± 0.03 mm (5.12 ± 0.0012 inch)	Ø 120.00 ± 0.5 mm (4.72 ± 0.02 inch)	37.1 ± 0.08 mm (1.46 ± 0.0031 inch)
7T-5038	Housing Assembly	7T-5039 8P-0955	Ductile	Ø 65.09 ± 0.013 mm (2.56 ± 0.0005 inch)	—	30.00 ± 0.250 mm (1.18 ± 0.01 inch)
8E-6574	Clutch Housing	8E-6574	Gray Cast Iron	Ø 158.74 ± 0.035 mm (6.25 ± 0.0014 inch)	Ø 134.98 ± 0.05 mm (5.31 ± 0.002 inch)	—
124-2744	Clutch Housing Assembly	124-2728	Ductile	Ø 215.81 ± 0.030 mm (8.50 ± 0.00118 inch)	Ø 194.00 ± 0.05 mm (7.64 ± 0.00197 inch)	—
218-3598	Housing	218-3598	Gray Cast Iron	Ø 129.97 ± 0.03 mm (5.12 ± 0.0012 inch)	Ø 120.00 ± 0.5 mm (4.72 ± 0.02 inch)	37.1 ± 0.08 mm (1.46 ± 0.0031 inch)
396-6503	Housing Assembly	396-6501	Ductile Iron Casting	Ø 94.96 ± 0.025 mm (3.739 ± 0.001 inch)	—	18.12 ± 0.15 mm (0.71338 ± 0.00591 inch)

Illustration 15	g01476660
(B) Diameter (C) Face (D) Pilot Bore Location (E) Diameter (F) Depth

Table 7

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 15
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (E)	Depth (F)
1T-1452	Housing Assembly	1T-1427	Ductile	Ø 129.99 ± 0.020 mm (5.12 ± 0.0008 inch)	Ø 101.63 ± 0.025 mm (4.00 ± 0.0010 inch)	25.07 ± 0.050 mm (0.99 ± 0.0020 inch)
1T-1819	Clutch Carrier	1T-1819	Ductile	Ø 199.96 ± 0.013 mm (7.87 ± 0.0005 inch)	—	55.42 ± 0.050 mm (2.18 ± 0.0020 inch)
8P-8551	Housing	8P-8551	Ductile	Ø 119.982 ± 0.030 mm (4.7237 ± 0.0012 inch)	Ø 88.95 ± 0.05 mm (3.5020 ± 0.002 inch)	49.10 ± 0.13 mm (1.9331 ± 0.005 inch)
8P-8551	Housing	9W-7708	Ductile	Ø 119.98 ± 0.030 mm (4.72 ± 0.0012 inch)	Ø 88.95 ± 0.050 mm (3.50 ± 0.0020 inch)	48.100± 0.050 mm (1.89 ± 0.0020 inch)
—	Housing	9W-8868	Ductile	Ø 129.99 ± 0.013 mm (5.12 ± 0.0005 inch)	Ø 101.63 ± 0.025 mm (4.00 ± 0.0010 inch)	48.94 ± 0.250 mm (1.93 ± 0.0098 inch)
—	Clutch Housing	258-5651 272-6433	Ductile	Ø 129.98 ± 0.03 mm (5.11 ± 0.00118 inch)	Ø 120.00 ± 0.5 mm (4.72 ± 0.02 inch)	59.39 ± 0.08 mm (2.34 ± 0.00315 inch)
264-2292	Clutch Housing	264-2292	Ductile	Ø 199.96 ± 0.013 mm (7.87 ± 0.0005 inch)	Ø 187.96 ± 0.25 mm (7.40 ± 0.01 inch)	55.42 ± 0.050 mm (2.18 ± 0.0020 inch)
360-5945	Housing Assembly	360-5944	Gray Cast Iron	Ø 185.50 ± 0.5 mm (7.30 ± 0.01969 inch)	Ø 121.00 mm (4.76 inch)	25.07 ± 0.08 mm (0.99 ± 0.0032 inch)

Illustration 16	g03190796
(B) Diameter (C) Face (D) Pilot Bore Location (F) Depth

Table 8

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 16
Part Number	Description	Casting Number	Material Type	Diameter (B)	Depth (F)
—	Housing	1T-0759	Gray Cast Iron	Ø 120.65 ± 0.025 mm (4.75 ± 0.0010 inch)	8.89 ± 0.051 mm (−.35 ± 0.0020 inch)
102-3733	Rotating Housing	102-3733	Ductile Iron Casting	Ø 300.00 ± 0.5 mm (11.81 ± 0.020 inch)	19.0 ± 0.5 mm (0.75 ± 0.02 inch)
357-7454	Converter Impeller	357-7454	Aluminum Casting	Ø 160.12 ± 0.035 mm (6.304 ± 0.0014 inch)	10.0 ± 0.13 mm (0.39 ± 0.005 inch)
364-8162	Impeller	364-8162	Aluminum Casting	Ø 160.12 ± 0.035 mm (6.304 ± 0.0014 inch)	10.0 ± 0.13 mm (0.39 ± 0.005 inch)
368-6505	Impeller	368-6505	Aluminum Casting	Ø 160.12 ± 0.035 mm (6.304 ± 0.0014 inch)	10.0 ± 0.13 mm (0.39 ± 0.005 inch)

Illustration 17	g03193179
(B) Diameter (C) Face (D) Pilot Bore Location (E) Diameter (F) Depth

Table 9

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 17
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (E)	Depth (F)
8E-4850 230-6302	Rotating Housing	8E-4850 230-6302	Ductile Iron Casting	Ø 378.61 ± 0.250 mm (14.91 ± 0.01 inch)	Ø 133.35 ± 0.030 mm (5.25 ± 0.0012 inch)	13.07 ± 0.130 mm (0.51 ± 0.0051 inch)
110-2144	Clutch Housing	110-2144	Ductile Iron Casting	Ø 518.00 ± 0.25 mm (20.39 ± 0.01 inch)	Ø 187.96 ± 0.25 mm (7.40 ± 0.01 inch)	8.08 ± 0.08 mm (0.32 ± 0.0032 inch)
205-4190	Rotating Housing	205-4190	Ductile Iron Casting	Ø 471.00 ± 0.040 mm (18.54 ± 0.0016 inch)	Ø 169.94 ± 0.050 mm (6.69 ± 0.0020 inch)	22.40 ± 0.13 mm (0.8819 ± 0.0051 inch)
226-7611	Rotating Housing	226-7611	Ductile Iron Casting	Ø 463.50 ± 0.080 mm (18.25 ± 0.0032 inch)	—	22.50 ± 0.500 mm (0.8858 ± 0.0197 inch)
226-7615	Rotating Housing	226-7615	Ductile Iron Casting	Ø 443.50 ± 0.130 mm (17.46 ± 0.0051 inch)	Ø 169.987 ± 0.013 mm (6.6924 ± 0.0005 inch)	22.50 ± 0.50 mm (0.8858 ± 0.0197 inch)
352-5692	Housing	352-5692	Ductile Iron Casting	Ø 378.61 ± 0.250 mm (14.91 ± 0.01 inch)	Ø 133.35 ± 0.030 mm (5.25 ± 0.0012 inch)	13.07 ± 0.130 mm (0.51 ± 0.0051 inch)

Illustration 18	g03193437
(B) Diameter (C) Face (D) Pilot Bore Location (E) Diameter (F) Depth

Table 10

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 18
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (E)	Depth (F)
6Y-2438	Housing	6P-8293 6Y-2438	Ductile	Ø 540.00 ± 0.080 mm (21.26 ± 0.0032 inch)	Ø 190.00 ± 0.080 mm (7.48 ± 0.0032 inch)	29.85 ± 0.050 mm (1.18 ± 0.0020 inch)
8E-8152	Rotating Housing	8E-8152	Ductile Iron Casting	Ø 463.50 ± 0.080 mm (18.25 ± 0.0032 inch)	Ø 210.00 ± 0.500 mm (8.27 ± 0.0197 inch)	9.00 ± 0.50 mm (0.35 ± 0.02 inch)
235-2416	Rotating Housing	235-2416	Ductile Iron Casting	Ø 393.55 ± 0.080 mm (15.49 ± 0.0032 inch)	Ø 137.00 ± 0.500 mm (5.39 ± 0.0197 inch)	7.00 ± 0.250 mm (0.28 ± 0.0098 inch)

Illustration 19	g03193877
(B) Diameter (C) Face (D) Pilot Bore Location (E) Diameter (F) Depth (G) Depth

Table 11

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 19
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (E)	Depth (F)	Diameter (G)
—	Converter Housing	1T-0614	Gray Cast Iron	Ø 385.85 ± 0.025 mm (15.19 ± 0.001 inch)	Ø 241.33 ± 0.025 mm (9.50 ± 0.001 inch)	22.00 ± 0.127 mm (0.87 ± 0.0050 inch)	19.050 ± 0.127 mm (0.7500 ± 0.005 inch)
—	Housing	1T-1094	Ductile Iron Casting	Ø 184.18 ± 0.025 mm (7.25 ± 0.0010 inch)	Ø 171.45 ± 0.025 mm (6.75 ± 0.0010 inch)	12.70 ± 0.051 mm (0.50 ± 0.0020 inch)	10.160 ± 0.025 mm (0.4000 ± 0.0010 inch)
210-3132	Rotating Housing	210-3132	Ductile Iron Casting	Ø 101.63 ± 0.030 mm (4.00 ± 0.0012 inch)	Ø 129.99 ± 0.020 mm (5.12 ± 0.0008 inch)	7.00 ± 0.080 mm (0.28 ± 0.0032 inch)	—
320-1236	Rotating Housing	1T-1549 320-1236	Ductile Iron Casting	Ø 184.18 ± 0.030 mm (7.25 ± 0.0012 inch)	Ø 174.75 ± 0.250 mm (6.88 ± 0.0098 inch)	12.70 ± 0.050 mm (0.500 ± 0.0020 inch)	11.180 ± 0.130 mm (0.4402 ± 0.0051 inch)
328-1501	Rotating Housing	328-1501	Ductile Iron Casting	Ø 184.18 ± 0.030 mm (7.25 ± 0.0012 inch)	Ø 171.45 ± 0.030 mm (6.75 ± 0.0012 inch)	12.70 ± 0.050 mm (0.5000 ± 0.0020 inch)	11.180 ± 0.250 mm (0.4402 ± 0.0098 inch)

Illustration 20	g03194337
(B) Diameter (C) Face (D) Pilot Bore Location (E) Diameter (F) Depth

Table 12

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 20
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (E)	Depth (F)
1T-0749	Housing	1T-0749	Aluminum Casting	Ø 177.80 ± 0.025 mm (7.00 ± 0.0010 inch)	Ø 120.65 ± 0.025 mm (4.75 ± 0.0010 inch)	3.24 ± 0.064 mm (0.13 ± 0.0025 inch)
—	Housing	1T-1843	Gray Cast Iron	Ø 104.32 ± 0.15 mm (4.11 ± 0.0059 inch)	Ø 89.99 ± 0.013 mm (3.54 ± 0.0005 inch)	12.74 ± 0.080 mm (0.50 ± 0.0032 inch)
—	Rotating Housing	1T-1849	Gray Cast Iron	Ø 104.32 ± 0.15 mm (4.11 ± 0.0059 inch)	Ø 89.99 ± 0.013 mm (3.54 ± 0.0005 inch)	12.74 ± 0.080 mm (0.50 ± 0.0032 inch)
1T-1866	Rotating Housing	1T-1866	Gray Cast Iron	Ø 104.32 ± 0.15 mm (4.11 ± 0.0059 inch)	Ø 89.99 ± 0.013 mm (3.54 ± 0.0005 inch)	12.74 ± 0.080 mm (0.50 ± 0.0032 inch)
—	Housing	1T-1883	Gray Cast Iron	Ø 98.57 ± 0.013 mm (3.88 ± 0.0005 inch)	Ø 89.98 ± 0.013 mm (3.54 ± 0.0005 inch)	12.14 ± 0.250 mm (0.48 ± 0.01 inch)
1T-1927 1T-1987	Rotating Housing	1T-1927 1T-1987	Gray Cast Iron	Ø 98.57 ± 0.013 mm (3.88 ± 0.0005 inch)	Ø 89.98 ± 0.013 mm (3.54 ± 0.0005 inch)	12.14 ± 0.250 mm (0.48 ± 0.01 inch)
183-7443	Housing Assembly	183-7442	Ductile Iron Casting	Ø 185.67 ± 0.050 mm (7.31 ± 0.0020 inch)	Ø 101.63 ± 0.025 mm (4.00 ± 0.0010 inch)	13.72 ± 0.250 mm (0.54 ± 0.0098 inch)
235-2415	Clutch Housing	128-7349 235-2415	Ductile Iron Casting	Ø 176.00 ± 0.500 mm (6.93 ± 0.0197 inch)	Ø 101.63 ± 0.030 mm (4.00 ± 0.0012 inch)	14.00 ± 0.13 mm (0.55 ± 0.0051 inch)

Illustration 21	g03291597
(B) Diameter (C) Diameter (D) Pilot Bore (E) Diameter (F) Depth (G) Face

Table 13

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 21
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (C)	Diameter (D)	Diameter (E)	Depth (F)
155-6189	Housing Assembly	155-5291	Ductile Iron Casting	Ø 559.37 ± 0.35 mm (22.02 ± 0.014 inch)	Ø 180.0 ± 0.5 mm (7.09 ± 0.02 inch)	Ø 158.80 ± 0.05 mm (6.252 ± 0.002 inch)	Ø 177.85 ± 0.05 mm (7.00 ± 0.002 inch)	18.00 ± 0.5 mm (0.71 ± 0.02 inch)

Illustration 22	g03291599
(B) Diameter (C) Face (D) Pilot Bore (E) Diameter (F) Depth (G) Depth

Table 14

Acceptable Bore Dimensions for Input Housing for the Torque Converter Refer to Illustration 22
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (D)	Diameter (E)	Depth (F)	Depth (G)
6Y-3608	Clutch Housing	6Y-3608	Ductile Iron Casting	Ø 215.015 ± 0.015 mm (8.4651 ± 0.0006 inch)	Ø 195.0 ± 0.5 mm (7.68 ± 0.02 inch)	Ø 429.80 ± 0.49 mm (16.921 ± 0.019 inch)	20.20 ± 0.5 mm (0.80 ± 0.02 inch)	116.00 ± 0.08 mm (4.567 ± 0.003 inch)

Illustration 23	g06423737
(A) Face (B) Diameter (C) Diameter (D) Diameter (E) Diameter (F) Depth

Table 15

Acceptable Bore Dimensions for Clutch Housing for the Torque Converter Refer to Illustration 23
Part Number	Description	Casting Number	Material Type	Diameter (B)	Diameter (C)	Diameter (D)	Diameter (E)	Depth (F)
391-4900	Clutch Housing	391-4900	Ductile Iron Casting	Ø 130.98 ± 0.13 mm (5.157 ± 0.0051 inch)	Ø 129.979 ± 0.03 mm (5.1173 ± 0.0012 inch)	Ø 80.962 ± 0.013 mm (3.1875 ± 0.0005 inch)	Ø 97 ± 0.5 mm (3.819 ± 0.01970 inch)	23 ± 0.25 mm (0.9055 ± 0.0098 inch)

Illustration 24	g06425419
(A) Diameter (B) Depth (C) Depth (D) Face

Table 16

Acceptable Bore Dimensions for Clutch Housing for the Torque Converter Refer to Illustration 24
Part Number	Description	Casting Number	Material Type	Diameter (A)	Depth (B)	Depth (C)
368-3592	Carrier Clutch	368-3592	Ductile Iron Casting	Ø 187.96 ± 0.25 mm (7.340 ± 0.0010 inch)	53.9 ± 0.08 mm (2.122 ± 0.003 inch)	61.98 ± 0.25 mm (2.440 ± 0.010 inch)
382-2704	Housing Clutch	382-2704	Ductile Iron Casting	Ø 187.96 ± 0.25 mm (7.340 ± 0.0010 inch)	55.42 ± 0.08 mm (2.182 ± 0.003 inch)	63.5 ± 0.25 mm (2.500 ± 0.010 inch)

Thermal Spray Procedure

Thermal spray is an acceptable method of restoring a surface to the original size. Consult the manufacturer of the equipment for metal spraying for recommendations of powder, machine settings, and procedures for application. Each step in the procedure is critical to achieving the desired coating, the desired bond, and the desired finish.

Note: Oerlikon Metco Inc. is one manufacturer of acceptable equipment for metal spraying and powder. Refer to Table 2for the website address of Oerlikon Metco Incorporated.

Part Description

Table 17

Base Metal	Cast Iron or Ductile Iron
Hardness	N/A

Flame Spray Equipment and Procedure

Table 18

Maximum Surface Texture	2.03 µm (80 µinch)
Mating Part Contact Area & Material	Bearing race
Metco Equipment Type	6PII ThermoSpray System
Metco Material	453
Finished Thickness	0.7620 mm (0.030 inch)
Finishing Allowance	0.51 mm (0.020 inch)
Spray Angle	As close to 90° as possible
Substrate Pre-Heat Temperature	85° C (185° F)
Substrate Temperature During Spraying Not to Exceed	149° C (300° F)
Rotation/Traverse Device	Lathe or turntable
Rotation/Traverse Speed	91.4 SMPM (300.00 SFPM)
Surface Preparation Method	Grit Blast
Finishing Method	Machine
Machining Equipment Type	Lathe
Recommended Cutter Grade	TRW 716 1058/883 or equivalent

Show/hide table

NOTICE
Do not direct the flame on area to be sprayed Locate part off housing Outside Diameter (O.D.) For machining, locate part off one of the original machined diameters.

Table 19

Flame Spray Process (6P)	Procedure	Check List
Clean Part	Degrease in hot caustic solution
Undercut	Not required
Chamfer	All edges - 45° x 7.6200 mm (0.300 inch)
Remove Oxide	Use clean emery paper or wire wheel or flapper wheel
Mask for Blast	Metal mask or duct tape
Blast Equipment	Suction cabinet
Grit Type and Size	G-25 angular steel
Blast Air Pressure	620 kPa (90.0 psi)
Blast Nozzle to Work Distance	63.5 mm (2.5 inch)
Remove Blast Mask	Remove
Mask for Spray	Use blast mask and METCO Anti-Bond
Spray Equipment Type	6PII ThermoSpray System
Nozzle	6P7C-K "K" nozzle
Air Capacity/Pressure	6P-3/Cooling air - 140 kPa (20.0 psi)
Extension	N/A
Air Jets/Pressure	N/A
Oxygen Pressure	206.8 kPa (30 psi)
Oxygen Flow	1190 L/h (42.0 cfh)
Fuel Gas Pressure	100 kPa (15.0 psi)
Fuel Gas Flow	1415 L/h (50.0 cfh)
Carrier Gas Pressure	380 kPa (55.0 psi)
Carrier Gas Flow	1050 L/h (37.0 cfh)
Spray Rate/Build Up	4.5 - 5.5 kg (10.00 - 12.00 lbs)per hour, 0.1016 - 0.1524 mm (.004 - 0.006 inch)
Gun to Work Distance	228.6 mm (9 inch)
Rotation Speed of Part (RPM)	Set RPM for desired SFPM
Rotation Speed of Part	91.4 SMPM (300.00 SFPM)
Gun Fixturing Method	Machine mount
Bond Pass/Thickness	0.1270 mm (0.005 inch)
Top Coat/Thickness	0.6350 mm (0.025 inch)
Finishing Equipment	Lathe
Part/Cutter Rotation (SFPM)	91.4 SMPM (300.00 SFPM)
Traverse Speed	0.51 mm (0.002 inch) to 0.10 mm (0.004 inch) per revolution
Depth of Rough Cut	0.25400 - 0.50800 mm (.010 - 0.020 inch)
Depth of Finish Cut	0.1270 - 0.25400 mm (.005 - 0.010 inch)
Additional Finish Method	Use fine emery (240 grit) for final polish