PRODUCT SUPPORT PROGRAM FOR REPLACING THE 1T1223 TORQUE CONVERTER SHAFT ON CERTAIN 773F OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING THE 1T1223 TORQUE CONVERTER SHAFT ON CERTAIN 773F OFF-HIGHWAY TRUCKS

Usage:

REBE6179-00

Show/hide table

21May2010

J421

Show/hide table

Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING THE 1T1223 TORQUE CONVERTER SHAFT ON CERTAIN 773F OFF-HIGHWAY TRUCKS
3101		PS43086

Show/hide table

NOTE:

This Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS43086" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Show/hide table

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.

Show/hide table

TERMINATION DATE

31May2011

PROBLEM

Show/hide table

The existing 1T1223 torque converter shaft can fail on certain 773F Off-Highway Trucks. If the existing shaft fails, the truck will loose drive and can fail engine crankshaft thrust bearings.

AFFECTED PRODUCT

Show/hide table

Model	Identification Number
773F	EED00286-00291, 312, 794-795, 801-802, 809-810, 820-823, 835-836, 839, 852, 861-862, 870-871, 873, 877-886, 892-893, 904-906, 921-924, 931, 964, 968, 972, 981-988, 994, 1005-1008, 1012-1013, 1055-1064

PARTS NEEDED

Show/hide table

Qty	Part Number	Description
2	0T0768	BOLT
1	1L7205	BEARING-BALL
1	1T0136	SEAL-O RING
3	1T1011	SHIM
3	1T1012	SHIM
1	1T1222	GASKET
1	4H6730	SEAL-O RING
2	6Y5888	RING-SEAL
2	8M4433	SEAL-O-RING
1	1395802	SEAL LIP-TYPE
1	3520384	SHAFT-OUTPUT
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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

Show/hide table

See attached rework procedure

Show/hide table

SERVICE CLAIM ALLOWANCES

Show/hide table

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%
0-16000 hrs, 0-48 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%

Show/hide table

NOTE: This is a 14.0-hour job

Show/hide table

PARTS DISPOSITION

Show/hide table

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

Rework Procedure

Show/hide table

Image1.1.1

Reference RENR8279 ?Torque Converter ? Remove? RENR8279 ?Torque Converter- Install?

Image1.2.1

1. Follow procedure RENR8279 ?Torque Converter ? Remove? to remove the torque converter assembly from the vehicle.

Image1.3.1

2. Remove six bolts (1) then remove pilot housing (2).

Image1.4.1

3. Remove two bolts (3) then remove retainer (4) and washer (8).

Image1.5.1

4. Remove retainer bolt (6), retainer (7), yoke flange (5), seal (9) and shims (10). Seal and shims not shown. Seal (9) will be replaced later.

Image1.6.1

5. Remove eight bolts (11), distributor (12), and gasket (13) not shown. Gasket will be replaced later with new.

Image1.7.1

6. Remove converter shaft assembly (17).

Image1.8.1

7. Remove two seals (15) from seal carrier (16). Seals (15) will be replaced later with new.

Image1.9.1

8. Place shaft assembly in appropriate support tooling and press to remove seal carrier (16) and bearing (14). Bearing will be replaced later with new.

Image1.10.1

9. Place new bearing (14) and seal carrier (16) in 300 F oven for 20 minutes. Install heated new bearing (14) and seal carrier (16) on new shaft (17). Allow assembly to cool.

Image1.11.1

10.Wrap new seals (15) in preparation for installation.

Image1.12.1

Image1.12.2

11. Install new seals (15) onto seal carrier (16). Lube seals with assembly aid lubricant.

Image1.13.1

12. Install converter shaft assembly (17).

Image1.14.1

13. Install washer (8), retainer (4), and two new 0T0768 bolts (3). Torque bolts to 80+/-10 N.m (59 +/- 7 lb ft).

Image1.15.1

14. Install new seal (18) with tooling ?C?.

Image1.16.1

15. Install tooling ?A?. Install new gasket (13) not shown and distributor (12).

Image1.17.1

16. Install eight bolts (11) and torque bolts to 50+/-7 N.m (35 +/- 5 lb ft).

Image1.18.1

17. Lubricate seal then install yoke flange (5).

Image1.19.1

18.Use Tooling (B) (not shown) to measure the distance between the end of output shaft (17) and the shoulder on flange (5). Record this Dimension as Dimension (W). Note: The thickness of the shims to use must have a total thickness of 0.13 to 0.25 mm (0.005 to 0.010 inch) less than the Dimension (W).

Image1.20.1

19. Install new O-ring seal (9), shims (10) as calculated in previous step, retainer (7), and retainer bolt (6). Tighten bolt (6) to a torque of 240 +/- 25 N.m (175 +/- 18 lb ft).
End By: Install the torque converter. Refer to Disassembly and Assembly, "Torque Converter - Install".