New Transmission And Torque Converter Pumps Need To Be Installed On Certain 797 Trucks Caterpillar

NOTE: This Program must be administered as soon as possible. When reporting the repair, use "PI30034" as the Part number and "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 "PI30034" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

Completion Date

Termination Date

Problem

New torque converter charge, transmission lube pump, the transmission charge, and scavenge pump need to be installed on certain 797 Trucks. The new pumps have an improved woodruff key, improved relief pockets, and improved pump flow at rated speed.

Affected Product
Model & Identification Number

797 (5YW213-222)

(Equipped with torque converter serial number of 5ST39 or below)

Parts Needed

Dealers will need to order parts for this Program.

1 - 8C5172 Seal

2 - 5F3144 O-Ring Seal

1 - 1H5728 O-Ring Seal

1 - 4H9105 O-Ring Seal

2 - 5H8848 O-Ring Seal

1 - 4J0527 O-Ring Seal

2 - 2M4453 O-Ring Seal

2 - 9M2092 O-Ring Seal

1 - 184-6034 Pump Group

1 - 185-8795 Pump Group

Action Required

Parts Stock

Remove all 152-0729 and 152-1125 Pump Groups from dealer Parts Stock.

Affected Product

See the attached procedure.

Owner Notification

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

Service Claim Allowances

Parts Stock

Submit one claim for all 152-0729 and 152-1125 Pump Groups removed from dealer Parts Stock.

Affected Product

Parts Disposition

Parts Stock

Return all 152-0729 and 152-1125 Pump Groups that are removed from Parts Stock and a copy of the claim to:

Affected Product
All Dealers

Return all 152-0729 and 152-1125 Pump Groups that are removed from the Affected Product and a copy of the claim to:

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

The latest Transmission control software Flash file 1889577 should be obtained from SIS and loaded into the Transmission control. Both pumps must be changed out simultaneously. Re calibration is required after installation of new software and pumps are completed.

Electronic Technican - requires Software version 3.1. This will be forwarded separately to affected Dealers.

PROCEDURE

1. Release the hydraulic pressure in the transmission and torque converter lines.

2. Remove (4) 8T-4184 bolts, (4) 8T-4223 washers, (2) 1P-4582 flanges, (1) 4J-0527 seal and disconnect (1) 171-9751 hose from the torque converter charge & transmission lube pump. Save the bolts washers and flanges for re-use. Refer to Callout (1) on Illustration 1.

3. Remove (4) 8T-4184 bolts, (4) 8T-4223 washers, (2) 1P-4582 flanges, (1) 4J-0527 seal and disconnect (1) 171-9751 hose from the torque converter charge & transmission lube pump. Save the bolts washers and flanges for re-use. Refer to Callout (1) on Illustration 1.

4. Remove (4) 8T-4140 bolts, (4) 9X-8257 washers, (2) 1P-7017 flanges, (1) 4H-9105 seal and disconnect (1) 163-1997 hose from the torque converter charge & transmission lube pump. Save the bolts, washers and flanges for re-use. Refer to Callout (3) on Illustration 1.

5. Remove (4) 6V-5684 bolts, (1) 5H-8848 seal and disconnect (1) 156-3935 tube from the torque converter charge & transmission lube pump. Save the bolts for re-use. Refer to Callout (4) on Illustration 1.

6. Remove (3) 6V-3823 bolts from the torque converter charge & transmission lube pump. Save the bolts for re-use. Remove (1) 152-1125 torque converter charge & transmission lube pump and (1) 2M-4453 and 5F3144 O-Ring Seal from the torque converter. Refer to Callout (5) on Illustration 1.

7. Remove (4) 6V-5686 bolts, (1) 9M-2092 seal and disconnect (1) 156-3939 tube from the transmission charge and scavenge pump. Save the bolts for re-use. Refer to Callout (6) on Illustration 2.

8. Remove (4) 6V-5686 bolts, (1) 9M-2092 seal and disconnect (1) 156-3941 tube from the transmission charge and scavenge pump. Save the bolts for re-use. Refer to Callout (7) on Illustration 2.

9. Remove (4) 8T-4184 bolts, (4) 8T-4223 washers, (2) 1P-4584 flange, (1) 5H-8848 seal and disconnect (1) 154-3372 hose from the transmission charge and scavenge pump. Save the bolts, washers and flanges for re-use. Refer to Callout (8) on Illustration 2.

10. Remove (4) 6V-5684 bolts, (1) 1H-5728 seal and disconnect (1) 156-4267 manifold from the transmission charge and scavenge pump. Save the bolts for re-use. Refer to Callout (9) on Illustration 2.

11. Remove (3) 6V-3823 bolts from the transmission charge and scavenge pump. Save the bolts for re-use. Remove (1) 152-0729 transmission charge and scavenge pump and (1) 2M-4453 and 5F3144 O-Ring Seal from the torque converter. Refer to Callout (10) on Illustration 2.

12. Install (1) 185-8795 transmission charge and scavenge pump and (1) 2M-4453 and 5F3144 O-Ring Seal to the torque converter. Install (3) 6V-3823 bolts to the transmission charge and scavenge pump. Use the bolts from Step 11. Torque the bolts to 100 ± 20 N·m. Refer to Illustration 3.

13. Connect (1) 156-4267 manifold to the transmission charge and scavenge pump and install (1) 1H-5728 seal and (4) 6V-5684 bolts. Use the bolts from Step 10. Torque the bolts to 100 ± 20 N·m. Refer to Illustration 3.

14. Connect (1) 154-3372 hose and install (4) 8T-4184 bolts, (4) 8T-4223 washers, and (2) 1P-4584 flange and (1) 5H-8848 seal to the transmission charge and scavenge pump. Use the bolts, washers and flanges from Step 9. Refer to illustration 2.

15. Connect (1) 156-3941 tube and install (4) 6V-5686 bolts and (1) 9M-2092 seal to the transmission charge and scavenge pump. Use the bolts from Step 8. Torque the bolts to 240 ± 40 N·m. Refer to Illustration 2.

16. Connect (1) 156-3939 tube and install (4) 6V-5686 bolts and (1) 9M-2092 seal to the transmission charge and scavenge pump. Use the bolts from Step 7. Torque the bolts to 240 ± 40 N·m. Refer to Illustration 2.

17. Install (1) 184-6034 torque converter charge & transmission lube pump and (1) 2M-4453 and 5F3144 O-Ring Seal to the torque converter. Install (3) 6V-3823 bolts to the torque converter charge & transmission lube pump. Use the bolts from Step 6. Torque the bolts to 100 ± 20 N·m. Refer to Illustration 1.

18. Connect (1) 156-3935 tube and install (4) 6V-5684 bolts and (1) 5H-8848 seal to the torque converter charge & transmission lube pump. Use the bolts from Step 5. Torque the bolts to 100 ± 20 N·m. Refer to Illustration 1.

19. Connect (1) 163-1997 hose and install (4) 8T-4140 bolts, (4) 9X-8257 washers, (2) 1P-7017 flanges and (1) 4H-9105 seal to the torque converter charge & transmission lube pump. Use the bolts, washers and flanges from Step 4. Refer to Illustration 1.

20. Connect (1) 156-3932 tube and install (4) 6V-5686 bolts and (1) 8C-5172 seal to the torque converter charge & transmission lube pump. Use the bolts from Step 3. Torque the bolts to 240 ± 40 N·m. Refer to Illustration 1.

21. Connect (1) 171-9751 hose and install (4) 8T-4184 bolts, (4) 8T-4223 washers, (2) 1P-4582 flanges and (1) 4J-0527 seal to the torque converter charge & transmission lube pump. Use the bolts, washers and flanges from Step 2. Refer to Illustration 1.

22. Check the oil level in the transmission and check the oil level in the torque converter. Add oil if necessary. Refer to SEBU7239 Operation and Maintenance Manual, "Torque Converter and Transmission Oil - Change" for more information on adding oil to the transmission and torque converter.

Failure to properly fill the torque converter sump may cause damage to the transmission clutches. Follow the procedure outlined in the Operations and Maintenance Manual.

Illustration 1.

Illustration 2.

Illustration 3.