PRODUCT SUPPORT PROGRAM FOR REPLACING DIFFERNTIAL DOWEL PINS ON CERTAIN 745 AND 745C ARTICULATED TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REPLACING DIFFERNTIAL DOWEL PINS ON CERTAIN 745 AND 745C ARTICULATED TRUCKS

Usage:

TEBE7546-00

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18Jun2018

K645
K646

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Containment - Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REPLACING DIFFERNTIAL DOWEL PINS ON CERTAIN 745 AND 745C ARTICULATED TRUCKS
3258		PS90899

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NOTE:

Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.

NOTE:

This Containment Program can be administered either before or after a failure occurs. In either case the decision whether to apply the Program is made by the dealer and service rep. Obtain the service reps Goodwill Approver Code before completing the repair. EAME dealers should use their standard Industry Group specific goodwill approval codes. The Goodwill Approver Code must be included when submitting the claim.

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NOTE:	When reporting the repair, use "PS90899" as the Part Number and "7777" as the Group Number. If administered before failure, use "56" as Warranty Claim Description and "T" as the SIMS Description Code. If administered after failure, use "96" as Warranty Claim Description Code and use "Z" as the SIMS Description Code.
NOTE:	The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.

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TERMINATION DATE

30Jun2020

PROBLEM

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The existing 544-1237 Dowel pressed into the 369-3407 Thrust Ring can fail on certain 745 and 745C Articulated Trucks. If the existing 544-1237 Dowel fails it may cause other parts to fail within the differential.

AFFECTED PRODUCT

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Model	Identification Number
745	3F600319, 321, 323, 325, 329, 331, 333, 469, 475, 477
745C	LFK00270, 578, 616, 836-837, 885, 906, 908, 1015, 1024, 1049, 1053, 1067, 1069-1071, 1073-1074, 1088-1089, 1091-1092, 1094-1096, 1112-1113

PARTS NEEDED

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Qty	Part Number	Description
3	5F9144	SEAL-O RING
1	8J8879	SEAL-O RING
3	1165897	SEAL-O-RING
3	2738666	SEAL-D-RING
3	2738667	SEAL-D-RING
1	2934503	SEAL-LIP TYPE
1	5249010	RETAINER
2	5249011	RETAINER
9	5564475	DOWEL-SPECIAL
1	LOCTITE	LOCTITE 5188 (As Required) Procure Locally
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 23% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.

ACTION REQUIRED

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Refer to the attached Rework Procedure.

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SERVICE CLAIM ALLOWANCES

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Product smu/age whichever comes first	Caterpillar		Dealer Suggested		Customer Suggested
Product smu/age whichever comes first	Parts %	Labor Hrs%	Parts %	Labor Hrs%	Parts %	Labor Hrs%
0-8000 hrs, 0-24 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
8001-12000 hrs, 25-36 mo	50.0%	50.0%	50.0%	50.0%	0.0%	0.0%
12001-15000 hrs, 37-48 mo	30.0%	33.0%	30.0%	34.0%	30.0%	33.0%

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NOTE: This is a 107.5-hour job
1 hour of the allowed labour is to cover the cost of machining as part of the additional work included in M0088900 to be performed while making this repair.

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PARTS DISPOSITION

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

Rework Procedure

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For removing and disassembly of the differential follow details as per M0082513.
For the Front & Rear differential you only need strip it down as far as step 33 in the D&A and for the Center differential only as far as step 34.
At this stage you are ready to perform the rework to install the new threaded Dowel pins into the Clutch Housing Plate.
Follow the next stages for installing new Dowels.

1. Remove the differential end plate (1.2.1) from assembly and remove the existing dowels if still in place.
2. Set up end plate in preparation for drilling and tapping operation on 3 holes (1.2.2) that dowels were removed from. Recommend the use of a vertical mill or drill press to assure new threads are perpendicular to the machined face of the plate.
3. Drill 3 holes with 12.7mm drill, tap through with M14x1.5
4. Clean and reinstall end plate to the differential case (1.2.3), tighten the 12x M16 bolts to a torque of 270Nm +/- 60Nm.
5. Apply Loctite 620 liberally to the threads of the new dowel. (1.2.4)
6. Thread into the housing until the dowel bottoms out. Locking pliers with soft jaws can be used to install if needed. (1.2.5)
7. Allow Loctite to cure before putting differential in contact with oil. Loctite activator can be used to accelerate the cure if there is a time constraint.

Image1.2.1

Image1.2.2

Image1.2.3

Image1.2.4

Image1.2.5

While the differential is removed and disassembled please also carry out the rework as specified in Special Instructions M0088900 to rework the "Center Differential Pinion Gear".
Note: This repair is only required on the Central Differentials and NOT the Front or Rear.