Usage:
NOTE: This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4540" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
NOTE: Although this Program is to be administered as described above on the Affected Product, parts should be removed from Parts Stock and reworked as soon as possible.
NOTE: This Revised Service Letter replaces the August 27, 1998 Service Letter. Changes have been made to the Parts Needed, Rework Procedure.
Termination Date
August 31, 2000Problem
The pinion gear in the 24H Motor Grader differential group may score or the thrust washers may not be retained properly. A lubrication package and new thrust washers can be installed.
Affected Product
Model & Identification Number
Differential Gear Groups In Parts Stock/Dealer Exchange
8X9042 ( Differential Gear Groups)
Affected Product
24H (7KK24-51, 7KK55, 7KK57)
Parts Needed
- 4 - 8C7562 SCREW-FLAT H
- 1 - 5D7523 SEAL-O-RING (not req'd for Parts Stock)
- 1 - 3J1907 SEAL-O-RING
- 1 - 4J1698 ORIFICE
- 1 - 6L1698 SPACER
- 1 - 5P9297 CLIP
- 1 - 6V1820 BOLT
- 1 - 6V5839 WASHER-HARD
- 2 - 6V8397 SEAL-O-RING
- 2 - 6V8781 TEE-FACE SEA
- 4 - 1546619 WASHER
- 1 - 1602728 TUBE AS.
- 1 - 1602729 TUBE AS.
- 1 - 5D7523 SEAL-O-RING (not req'd for Parts Stock)
Action Required
See the attached procedure.
Service Claim Allowances
NOTE: This is a 44-hour job.
NOTE: If there has been a previous repair, part age will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
- (1-Rework Procedure)
Rework Procedure
1. Remove the differential from the machine. The following tooling may be used to aid in the removal and lifting of the differential:
- 1 x 142-6893 Adjustable Hook Assembly
- 1 x 143-7597 Differential Lifting Bracket
- 4 x 8T-0667 Bolt
- 1 x 143-7597 Differential Lifting Bracket
2. Disassemble the differential. The following parts need to have some machine work done to them:
2A-7178 Housing - machining required
1. Machine the thrust washer surface depth from 1.29 ± 0.05 mm as shown in Illustration 1.
Illlustration 1
2. Machine the counterbore for the 8C-5762 Screws and tap the threads as shown in Illustrations 2 and 3.
Illlustration 2
Illlustration 3
- 2A-7322 Housing - machining required
1. Machine the thrust washer surface depth from 117.25 ± 0.08 mm to 118.54 ± 0.08 mm as shown in Illustrations 4 and 5.
Illlustration 4
Illlustration 5
2. Machine the counterbore for the 8C-5762 Screws and tap the threads as shown in Illustrations 3 and 5.
3. Check the 226.06 ± 0.25 mm diameter as shown in Illustration 6. Machine to the proper dimension as necessary.
Illlustration 6
2A-7163 Pinion Housing
1. Machine and tap the threads for a 10 mm bolt and add a spot face as shown in Illustration 7. Machine and tap the threads for a No. 6 Port as shown in Illustration 7.
Illlustration 7
2. Add the cross drilled passage as shown in Illustrations 7 and 8.
Illlustration 8
3. Tap the threads for the orifice plug as shown in Illustration 9.
Illlustration 9
Reassembly of the differential
1. Refer to Service Magazine article dated 13APR98 pages 36 - 40 for the appropriate assembly specifications of the 24H differential.
2. Refer to pages 1 and 2 of SEBF8119, Reusability Guidelines for Differential Components, to determine reuseability of the 125-5721 Pinion Shaft. If the 125-5721 Pinion Shaft is not reusable it should be replaced with a 154-2728 Pinion Shaft. The old 116-8238 Ring Gear can be reused with a new pinion if it meets the appropriate reusability guidelines.
3. See Illustrations 10 and 11 for the location of the forced lube package parts.
Illustration 10
Illlustration 11
4. Replace the four 3D-6509 Dowels and two 3D-8513 Thrust Washers with four 8C-7562 Screws and two 154-6619 Thrust Washers. Tighten the four 8C-7562 Screws to 28 ± 7 N·m. Use 4C-4030 Loctite on the screw threads prior to assembly.