PSP FOR REPLACING FAILED CYLINDER HEAD GASKETS ON CERTAIN 3406B TRUCK ENGINES - EFFECTIVE OCTOBER 09, 1990 - PS6040 - THI S SL CANCELS AND REPLACES APRIL 12, 1990 (REVISED AUGUST 1990) SL - PS0450 - MAILED US AND CANADA, COFA, CFEL, TRUCK TEPS, LIMIT Caterpillar

December 3, 1990
(Effective October 9, 1990)
(Revised December 1991)
U-240
AU-151
E-146
O-183.3
TT-19
PRODUCT SUPPORT PROGRAM FOR REPLACING FAILED CYLINDER HEAD GASKETS ON CERTAIN
3406B TRUCK ENGINES
1124   PS6040
NOTE: This Program can only be administered after a failure occurs.
The decision whether to apply the Program is made by the dealer.
When reporting the repair, use "PS6040" as the Part Number and
"7755" as the Group Number. Use "96" as the Warranty Claim
Description Code and use "Z" as the SIMS Description Code.
NOTE: This Revised Service Letter replaces the December 3, 1990
(Revised March 1991) Service Letter. Changes have been made to
include the October 31, 1991 Service Letter Supplement.
Additional changes were made to the Termination Date, Action
Required, Service Claim Allowances, and Parts Disposition.

March 31, 1992

The cylinder head gasket may fail on certain 3406B Truck Engines and result
in damage to the cylinder block, spacer plate, and/or cylinder head.

Model Identification Number
3406B 7FB86000-Up
8SB1695-2514
7XC408-1549
8TC1-8518
4MG1-62276

*1 - Gasket Kit-Cylinder Head
1 - Gasket-Oil Pan
**1 - 9L5854 Band (Filler)
***1 - 5N0093 Insert (.106")
**2 - 7E5665 Retainer
**3 - 6V5121 Seal
***1 - 2W3815 Insert (.060")
**1 - 2W8601 Plate-Spacer
**1 - 7W3550 Liner
***1 - 9Y3368 Insert (.030")
**1 - 9Y9497 Rod Bearing
* Part number varies by application. See the parts book microfiche and
choose the appropriate gasket kit. Make sure the gasket kit contains the
7E6000 Cylinder Head Gasket.
** Quantity listed is per cylinder.
*** Use as required.

Refer to the following reference articles:
#1 Service Magazine, August 6, 1990, "Coolant Loss In 3406B Truck Engines"
#2 "Know Your Cooling System" SEBD0518 pages 22 and 23
#3 Service Magazine, November 26, 1990, "Service Tips for Piston Cooling
Jets (Tubes)"
#4 Service Magazine, November 14, 1988, "New Liner Seat Available For 3400
Engines"
#5 Special Instruction SMHS8222 "Installation of 2W3815 or 5N0093 Inserts"
#6 Guideline for Reusable Parts SEBF8131 "Spacer Plates for 3400 Engines"
#7 Guideline for Reusable Parts SEBF8049 "Pistons" - page 25
#8 Guideline for Reusable Parts SEBF8051 "Piston Pins and Retaining Rings"
#9 Service Magazines, January 30, 1989 "Head Gasket Replacement Guidelines"
and "Liner Projection"
#10 Applied Failure Analysis - Threaded Fasteners SEBV0545
Steam clean the engine if needed.
Perform the "bottle test" for exhaust gas leakage as described in "Know Your
Cooling System" SEBD0518 pages 22 and 23. Record the results in the service
report. If no exhaust gas leakage is evident with the "bottle test", this
Program does not apply.
Check the timing advance unit operation with the 6V3100 (or 8T5300 & 8T5301
Adapter) Timing Indicator Group.
Check all fuel settings on governors that are not factory sealed and record
the before and after settings in the service report. This Program cannot be
applied to engines operating out of factory specifications.
Remove the cooling jets and inspect per reference #3.
Remove all six cylinder packs from the engine using the 6V9448 Puller.
Inspect the flatness of the cylinder head and block per the Service Manual
Specifications. If the bottom surface of the cylinder head is damaged,
repair by machining while maintaining minimum head thickness specifications.
If damage is excessive and/or if time constraints dictate, use a
remanufactured cylinder head. If salvage cost to recondition the head
exceeds the cost of a remanufactured cylinder head, use the latter option in
the repair.
Inspect the block for "measurable" liner seat damage (.001") under the
flanges and record these measurements in the service report.
Install inserts only in the cylinders that require them per reference #5.
Use only stainless steel inserts.
Inspect the spacer plates for reusability as described in reference #6.
Measure the liner flange thicknesses and replace if the liner flange is out
of specification.
Replace all piston pin retainers by pulling the pistons half way out of the
bottom of the liners on the bench. Since rod bushing wear of up to .010"
is reusable, it will not be necessary to measure these parts. See
reference #3. This specification of .010" supersedes what is in the
Service Manual.
Pistons are reusable if the pin can be slid across the retainer groove and if
a new retainer is tight in the groove as described in references #7 and #8.
NOTE: It is normal for some pins to resist movement within the piston
bores at room temperatures. Clearances open up during engine
operation.
Replace all liner filler bands and o-rings. Lubricate the filler bands with
oil and lubricate the o-rings with soap. Install the cylinder packs with new
connecting rod bearings before the liner band swells. Measure and record the
liner projection measurements in the service report per reference #9.
NOTE: New main bearings are not included in this Program.
Assemble the engine using a new 7E6000 Head Gasket. Replace the head bolts
that have surface damage which cannot be polished smooth as described in
reference #10. Install the cylinder head bolts and tighten to the correct
specifications as described in the Service Manual. Use 6V4867 Molycoat on
the threads and under heads of the bolts. Do not replace a cylinder head for
suspected internal leakage unless a crack is visible or the cylinder head is
checked for leaks after it is installed using a new head gasket and the
nozzle adapters have been checked for possible gasket leakage. Do not mark
cylinder heads as "Cracked" unless a crack is verified by the above methods.
A cracked cylinder head cannot be remanufactured.

Product Caterpillar Dealer Suggested Customer Suggested
mile/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor %
Whichever
comes
first
0-300,000 100% * 0 0 0 0
0-60 mo
300,001- ** ** 0 0 ** **
500,000
0-60 mo
* File claim as shown in the following chart. Caterpillar will pay 100% of
the labor from 0-300,000 miles or 0-60 months.
SMCS Hours Description
1000-74 .6 Steam Clean
1000-38 1.0 Diagnostic Time To Verify Complaint
1299-082 .8 Timing Advance Unit (Check Dynamically -- Initial
& Adv Timing)
1257.082 .9 Fuel Rack/Control Shaft Check - Full Load, Full
Torque, FRC Setting
1239-10 21.1 R&I Set of Cylinder Packs For Conventional
or 23.1 For K6 Conventional
or 23.9 For Short Conventional
or 21.3 For Cab Over
1216-082 1.2 Measure Liner Projection
1000-30 1.0 Test After Repair
(The following if required)
1100-02 1.8 Cylinder Head Exchange
1119-10 1.0 R&I Engine Brake
1302-10PH 1.0 R&I Pan Plate (Sound Suppression)
1217-012F 1.5 Install First Liner Insert
1217-012A .7 Each Additional Insert
1217-012S 5.0 Install A Set Of 6 Inserts
** Refer to the following chart for the percentage of the parts and the
percentage of the labor that Caterpillar will pay. File claim for labor
as shown in the preceding chart.
Mileage Caterpillar
Participation
300,000 - 310,000 100%
310,000 - 320,000 95%
320,000 - 330,000 90%
330,000 - 340,000 85%
340,000 - 350,000 80%
350,000 - 360,000 75%
360,000 - 370,000 70%
370,000 - 380,000 65%
380,000 - 390,000 60%
390,000 - 400,000 55%
400,000 - 410,000 50%
410,000 - 420,000 45%
420,000 - 430,000 40%
430,000 - 440,000 35%
440,000 - 450,000 30%
450,000 - 460,000 25%
460,000 - 470,000 20%
470,000 - 480,000 15%
480,000 - 490,000 10%
490,000 - 500,000 05%
NOTE: See the labor breakdown for repair times.
NOTE: If repair is performed in conjunction with an in-frame overhaul,
apply the service claim allowance toward the cost of the
overhaul.

Warranty claim parts that do not involve core credit must be held for 30 days
after the Caterpillar Claim Register Date. Warranty claim parts that involve
core credit must be held for 15 days after the Caterpillar Claim Register
Date.
NOTE: Failure to clearly mark the area of the cylinder head failure can
result in claim credit being denied.