The Transmission Needs To Be Inspected And Reworked If A Lubrication Passage Is Missing On Certain 950G, And 962G Wheel Loaders; And IT62G Integrated Toolcarriers Caterpillar

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI3227" 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 "PI3227" 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 December 11, 1998 Service Letter. Changes have been made to the Action Required and Service Claim Allowances.

NOTE: Changes were made to provide for in-chasis rework of the transmission only.

Completion Date

Termination Date

Problem

Oil to lubricate the transmission, enters the transmission through a tube that is bolted to the 118-4264 Reverse Clutch Housing Assembly on the right hand side of the vehicle. Most of the oil passes through a 'cored' passage in the casting and flows to the direction and 2nd through 4th speed planetaries. A 7 mm hole is drilled in the 118-4264 Housing As. This hole is intended to direct oil to the 1st speed planetary.

On some of the transmissions, the 7 mm hole was not drilled deep enough to intersect with the cored passage. If these two passages do not intersect there may be insufficient oil to lubricate the bearings, gears and clutch discs of the low speed planetary.

Affected Product
Model & Identification Number

950G (2JS251, 2JS254-272, 2JS274-466, 2JS468-471, 2JS473, 2JS478, 2JS480, 2JS487 3JW276 , 3JW292, 3JW296, 3JW300, 3JW319, 3JW339, 3JW343, 3JW345, 3JW349-350, 3JW352-354, 3JW358-364, 3JW366, 3JW368-369, 3JW372-374, 3JW376-381, 3JW387-389, 3JW392-393, 3JW395-400, 3JW402, 3JW405-416, 3JW418-420, 3JW422-425, 3JW428-435, 3JW437, 3JW440-441, 3JW444-449, 3JW451-455, 3JW457-459, 3JW462-471, 3JW478, 3JW482-489, 3JW491, 3JW499-500, 3JW503-512, 3JW514-521, 3JW524-532, 3JW534-555, 3JW557-578, 3JW581, 3JW583-585, 3JW587, 3JW589-591, 3JW593-598, 3JW600-617, 3JW620-628, 3JW630-633, 3JW636-637, 3JW640-641, 3JW651-657, 3JW660, 3JW662-674 4BS258-261 , 4BS263-265, 4BS267-272, 4BS274-278, 4BS280, 4BS283-284, 4BS286, 4BS289, 4BS291-293, 4BS295, 4BS297-298, 4BS300, 4BS303-304, 4BS306-314, 4BS317-339, 4BS342-345, 4BS342-345, 4BS348-355, 4BS358-361, 4BS364-390, 4BS392-393, 4BS407-410, 4BS412-413 8JW196 , 8JW198, 8JW199, 8JW211, 8JW213, 8JW214, 8JW241 5FW295 , 5FW313, 5FW363, 5FW365, 5FW368, 5FW369, 5FW371, 5FW378, 5FW381-383, 5FW385-405, 5FW408-411, 5FW413-415, 5FW417-461, 5FW464-474, 5FW476-479, 5FW481-483, 5FW485-683, 5FW685-713, 5FW715-720, 5FW722-727, 5FW730, 5FW732, 5FW735, 5FW736, 5FW738, 5FW739, 5FW741)

962G (3BS217-236, 3BS238-337, 3BS355 4PW209-210 , 4PW212-214, 4PW216, 4PW218-223, 4PW225-227, 4PW229-231, 4PW234, 4PW236-258 5AS218 , 5AS220, 5AS223-226, 5AS228-262, 5AS264-271 6EW208-212 7BW222 , 7BW235, 7BW237, 7BW238, 7BW242-256, 7BW258-318, 7BW320-355, 7BW357)

IT62G (6PS347, 6PS349-354, 6PS356-357, 6PS364-365)

Parts Needed

Dealers will need to order parts for this Program.

1 - 7H3171 Plug

1 - 1U8846 Gasket Maker (or Teflon tape)

1 - 9T5916 Filter-Oil

34 Liters Drive Train Oil

NOTE: These parts are for units requiring inspection and/or rework and with less than 500 hours.

An estimated 15 to 20 machines will have over 500 hours by the time that this Program is implemented. In these cases refer to the action required.

Action Required

All affected machines must be inspected as per the Inspection Procedure that is attached. If the 7mm diameter lubrication hole is not found during the inspection the transmission is to be reworked in chassis as per the attached rework procedures.

Owner Notification

U.S. and Canadian owners will receive the attached Owner Notification.

Service Claim Allowances

NOTE: This is a 4-hour job to inspect the transmission.

NOTE: Under certain circumstances more than one trip to the jobsite/machine will be required since it may not be possible to complete the inspection and the rework portions of this program at the same time.

NOTE: Machines with less than 500 SMU that have the transmission reworked in chassis will require an additional 6 hours of labor.

Parts Disposition

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

NOTE: MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.

Attach.

(1-Owner Notification)

(2-Rework Procedure)

Copy Of Owner Notification For U.S. And Canadian Owners

Rework Procedure

950G/962G/IT62G Transmission

Contents:

1 - Special Tools:

2 - Inspecting the Transmission

3 - Reworking the Transmission

4 - Clean Up & Start Up

NOTE: This in-frame rework has been validated. However, critical to the success of this rework is the clean up and start up. Please read the procedures for clean up before starting rework.

Special Tools:

A 170-5891 Tool (not serviced separately) is used to inspect the transmission. An Illustration of the tool, which can be dealer fabricated, is shown at the bottom of the page.

A 170-5752 Service Kit is used to rework transmissions. The 170-5752 Service Kit includes: a drill fixture, a special drill, a drill collar, a special tap, a tap fixture and the 170-5891 Tool. Four 6V4248 bolts must be added to the Service Kit for use with the drill fixture.

The 170-5752 Service Kit is available through parts distribution. This service kit can be reused on many machines. Distribution of the Service Kit will be controlled to ensure that all dealers have an opportunity to order and receive the kit when they first become available in limited quantities.

A provision must be made to 'vacuum' out the cored passage. A common Wet & Dry or a shop vac may be used with the lines reduced to a size that will enter into the passage. Or a venturi may be assembled out of common pipe and plumbing fixtures and shop air applied to venturi to pull a vacuum. The vacuum transducer commonly used when working with hydraulic systems may not (if worn) create enough suction to draw chips out of the passage.

Inspecting the transmission:

1. Start by removing guards and tilting the hood to gain access to the transmission on the right hand side of the vehicle.

2. Remove the bolts and washers holding the 128-1680 Tube As. (item 10) to the transmission. Loosen the bolt (item 18 & 20) holding the clamp allowing the tube as. to be moved to the side. Plug all lines removed to prevent dirt entry.

3. Loosen the bolt holding the fuel line. The bolt is shown in section view DD.

4. Use the 170-5891 Tool to probe for the 7mm hole in the 118-4264 Housing Assembly. See the next Illustration.

5. Insert the 170-5891 tool into the lube passage with the curve down. With the tip of the tool resting on the bottom of the cored passage, follow the wall (as illustrated above with the heavy broken) line until the washer (handle) is nearly flush with the housing. If the 7 mm hole intersects with the cored passage, the pin on the end of the tool will catch on the 7 mm hole. When the hole is present, it is easily found. If the hole is not present, the inspector will typically repeat the process several times before convincing himself that the part is incorrect.

6. If the 7 mm hole is present, no further action is required. Reinstall all lines and guards.

7. If the 7 mm hole can not be felt the transmission requires rework.

Reworking the transmission.

While not required, blocking up the rear of the machine and removing the right rear wheel will provide better access to rework the transmission.

1. Using 4-6V4248 bolts, install the drill guide to the transmission, bolting it to the four bolt pattern from which the tube was removed.

2. Install the collar on the drill bit. The collar is located 80 mm from the 'corner' of the drill.

3. Use a right angle drill. If necessary, insert the drill bit in the drill guide before chucking the bit in the drill.

4. Before drilling the hole, insert the vacuum line through the cored passage. A inch internal diameter plastic line works well. Attach the plastic line to the vac or other suction device. Cut the other end of the line at 45 degrees to increase the size of the opening. Insert the plastic tube into the cored passage, approximately 90 to 95 mm. At this depth the plastic line will be near or at the location the drill will 'break out' into the cored passage.

5. Following the guide, drill up into the transmission housing. This process works best with two men. One standing beside the machine to control the drill. A second man can be underneath the machine applying pressure to the drill using a heavy screw driver or bar.

A. For best results, use low to medium drill speeds with high drill pressure during the initial stages of drilling. This will result in the drill cutting larger chips.

B. When the collar is within .75 in. or 20 mm from the guide increase the drill speed and decrease the pressure on the drill. The higher drill RPM and lower pressure will result in fewer large chips.

C. Continue to drill until the drill collar contacts the drill guide.

6. Remove the drill and drill guide.

7. To avoid cross threading install the tap guide on the clutch housing. When using the guide the tap can be turned with an ordinary socket wrench. Cut the initial threads for the plug (about three complete turns of the Tap.) Because of the limited space, it will be necessary to remove the tap, and tap guide and then finish cutting the threads. Run the tap in until the last flute is showing on the tap. This will permit the plug, when installed, to be flush with the housing.

8. Do not install the plug until it is called for in the clean up & start up procedure.

Clean Up & Start Up

NOTE: Use of a flexible pencil magnet is part of this rework. This magnet is your final check to ensure all chips are removed as per step 12 of this procedure. Prior usage may magnetize chips and hinder cleanup.

1. While drilling, it is important to use the vacuum line to catch as many chips as possible.

2. While drilling work the drill bit in and out to help draw the chips out of the drilled passage and clear the flutes.

3. When the drill bit starts to break out into the cored passage small amounts of oil can be poured into the cored passage. This oil will run into the drilled passage and help to wash the chips out.

4. When drilling is complete, use a seal pick or similar instrument to knock off any burrs which may be present.

5. Return with the vacuum line and again clean around the drilled passage.

6. Apply compressed air at the transmission fill tube, to pressurize the transmission. A shop rag or towel wrapped around a nozzle on the air line will provide an adequate seal.

NOTE: The transmission case should not be highly pressurized. An estimated 0.5 bar (5 to 10 psi) pressure in the case will do the job. If possible use a regulator on the air line. With a shop towel wrapped around the airline, between 5.0 and 6.5 bar (70 to 90 psi) at the air line will provide sufficient pressure in the case.

Keep the transmission pressurized while watching for chips and debris to be blown out of the cored and drilled passages.

7. Install the transmission cooler line to the transmission.

8. Remove both wires from the fuel shutoff solenoid. (With the shutoff solenoid deactivated, the engine will not start).

9. Crank the engine for 4 to 5 seconds to force oil through the cooler and flood the inlet to the transmission.

10. Reapply compressed air at the transmission fill tube and observe the oil blown through the drilled passage.

11. Repeat steps 10 and 11 until no more contaminants can be flushed from the drilled passage.

12. Remove the line from the oil cooler and use a small pencil type magnet only to verify that all chips have been removed. Pass the magnet into both the cored and drilled passages. If there are metal chips on the magnet when it is removed, repeat steps 9, 10, 11. Reinstall the line from the oil cooler.

13. Reinstall both wires to the fuel shutoff solenoid.

14. Install the 7H3171 Plug using Teflon tape or 1U8846 Gasket Maker.

15. Start the machine. Leaving the transmission in neutral run the engine for a minimum of 10 minutes at low idle. After 10 minutes, keeping the transmission in neutral run the engine an additional 5 minutes at high idle.

16. Remove the filter element and discard. Install a new filter element. Remove, clean, and reinstall the magnetic screen.

17. Drain the used oil from, and refill, the transmission to proper level.

18. Reinstall all lines, clips, and guards.

19. Inspect the lip seals and yokes at the output transfer gear group to make sure oil did not leak past the seals while the transmission case was pressurized. Wipe up any oil that may have leaked.