New Adapter And Fuel Cap Need To Be Installed On Certain Challenger 65 And Challenger 75 Tractors Caterpillar

New Adapter And Fuel Cap Need To Be Installed On Certain Challenger 65 And Challenger 75 Tractors

Usage:

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Caterpillar: Confidential Yellow

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI1181" as the Part Number, "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 "PI1181" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

NOTE: This Revised Service Letter replaces the January 24, 1992 Service Letter.Changes have been made to the Affected Product

Problem

A new adapter and fuel cap need to be installed on certain Challenger 65 and Challenger 75 Tractors to prevent fuel leakage in certain applications.

Affected Product
Model & Identification Number

Ch 65^*(7YC1-1937, 7YC1939-1941, 7YC1943-1951, 7YC1953-1956, 7YC1958, 7YC1959, 7YC1961, 7YC1963-1965, 7YC1967-1971, 7YC1973, 7YC1975-1978, 7YC1980, 7YC1982, 7YC1984-1994, 7YC1996-2002, 7YC2004-2007, 7YC2009, 7YC2011-2020, 7YC2023, 7YC2028, 7YC2030-2035, 7YC2037, 7YC2040, 7YC2042-2046, 7YC2050, 7YC2051, 7YC2054-2056, 7YC2061, 7YC2064, 7YC2065, 7YC2068, 7YC2069, 7YC2071-2077, 7YC2079-2082, 7YC2086-2088, 7YC2090-2093)

Ch 75^**(4CJ1-335, 4CJ337-340, 4CJ342, 4CJ344-348, 4CJ350-352, 4CJ354-356, 4CJ375-378, 4CJ380-394, 4CJ396, 4CJ397, 4CJ399-402, 4CJ404, 4CJ407-435)

^*7YCl-2009 are equipped with a non-metallic tank and 7YC2010-2086 are equipped with a metal tank.

^**4CJ1-240 are equipped with a non-metallic tank and 4CJ241-431 are equipped with a metal tank.

Parts Needed

Dealers will need to order parts for this Program.

12 - 1H3337 Bolt (7YC2010-2086 and 4CJ241-431 only)

2 - 2H3088 Ring (7YC1-2009 and 4CJ1-240 only)

2 - 8J1688 Seal-o-ring (7YC2010-2086 and 4CJ241-431 only)

12 - 3N2156 Screw (7YC1-2009 and 4CJ1-240 only)

1 - 1U8846 Gasket Maker (use only as required)

2 - 9U3015 Filler Assembly (7YC2010-2086 and 4CJ241-431 only)

2 - 9U3347 Adapter (7YC1-2009 and 4CJ1-240 only)

1 - 6V1541 Primer (use only as required)

2 - 7X7700 Cap Assembly-Fuel

Action Required

Parts Stock

Remove all remaining quantities of 3W6882 Cap Assemblies from parts stock.

Affected Product

7YC2010-2086 and 4CJ241-431

1. Remove the existing fuel cap adaptor from the tank. Save the 8T4205 Washers for reuse. Clean the seal face on the tank.

2. Install the new 9U3015 Filler on the tank using a new 8J1688 Seal, new lH3337 Bolts, and the washers saved in step one.

3. Install the new 7X7700 Cap Assembly.

7YC1-2009 and 4CJ1-240

1. Thoroughly clean dirt and fuel residue from inside the tank's filler neck and from its top.

2. Push a 2H3088 O-ring Seal down over the projection on the adaptor so it is against the flange.

3. Spray the o-ring, the flange and .5" of the projection on the adaptor, the top surface of the tank filler neck, and .5" down inside the fuel filler neck with 6V1541 Primer.

4. Run a generous bead of lU8846 Gasket Maker around the o-ring and on the adjacent flange on the adaptor.

5. Insert the adaptor into the tank and screw it in by hand so the flange on the adaptor and the flange on the tank are in solid contact with each other.

6. Using the holes in the adaptor as a guide, drill a .062" diameter hole in each, approximately .5" deep. fill each with gasket maker. spray each 3N2156 Screw with primer before installing it. Be cautious to avoid over tightening and stripping the threads the screw cuts in the filler neck.

7. Install the new 7X7700 Cap.