PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIFFERENTIAL ON CERTAIN 789D OFF-HIGHWAY TRUCKS Caterpillar

PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIFFERENTIAL ON CERTAIN 789D OFF-HIGHWAY TRUCKS

Usage:

TEBE8653-00

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26Apr2019

H160

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Before/After (Limited distribution)	PRODUCT SUPPORT PROGRAM FOR REWORKING THE DIFFERENTIAL ON CERTAIN 789D OFF-HIGHWAY TRUCKS
3258 3256 3281		PS46241

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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 Program must be administered either before or after failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS46241" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and "T" as the SIMS Description code. If administered after failure, use "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.

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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

30Apr2021

PROBLEM

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The existing differential can experience accelerated thrust washer wear on certain 789D Off-Highway Trucks. If the existing thrust washer fails it can cause machine downtime for repair.

AFFECTED PRODUCT

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Model	Identification Number
789D	SPD00171, 276, 297-298, 308, 312, 435, 446, 448, 475, 477, 531-533, 539, 552, 693-695

PARTS NEEDED

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Qty	Part Number	Description
1	5D6428	SEAL-O-RING (After Failure Only)
1	5M7329	SEAL-O-RING (After Failure Only)
1	5P4540	BEARING-CUP (After Failure Only)
1	5P9519	SEAL-O RING (After Failure Only)
1	6V0459	BEARING-CONE (After Failure Only)
1	6V0460	BEARING-CUP (After Failure Only)
12	1326757	SHIM (After Failure Only)
10	1326758	SHIM (After Failure Only)
1	1335098	BEARING-CONE (After Failure Only)
1	1335099	BEARING-CUP (After Failure Only)
1	1335101	BEARING-CONE (After Failure Only)
1	1335102	BEARING-CUP (After Failure Only)
1	3871379	SEAL AS (After Failure Only)
1	4364013	BEARING-CONE (After Failure Only)
2	4480727	GEAR-DIFF BEVEL
2	4532978	BEARING-THRUST
2	4532979	BEARING
4	5692647	PINION-DIFF
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 29% 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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During PCR, rework the two halves of the differential housing per the images provided. Reassemble the differential with the new roller thrust bearing and race, side gears and spider gears.

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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%
0-6000 hrs, 0-12 mo	100.0%	100.0%	0.0%	0.0%	0.0%	0.0%
6001-12000 hrs, 13-24 mo	33.0%	50.0%	0.0%	0.0%	50.0%	50.0%
12001-18000 hrs, 25-48 mo	13.0%	25.0%	0.0%	0.0%	65.0%	75.0%

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NOTE: This is a 4.0-hour job If there has been a previous repair, part age/hours 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.
A flat amount of $2800 USD will be allowed for reworking the existing differential housing to accept the new thrust bearings. The intent of this program is for the update to be completed during a PCR. In the event a differential fails prior to scheduled repair an additional 44 labor hours can be claimed in addition to the "after failure only" parts.

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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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During PCR, rework the two halves of the differential rotating housing using the illustration below. 570-2403 is the plain half and will be made from the existing 130-6443 Housing. 570-2406 is the flanged half and will be made form the existing 7I-5877 Housing. Reassemble the Differential with the bearings and gears included in the parts list.