PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION AFTER FAILURE ON CERTAIN 735C, 740C EJ, 745C, 740 EJ, AND 745 ARTICULATED TRUCKS Caterpillar


PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION AFTER FAILURE ON CERTAIN 735C, 740C EJ, 745C, 740 EJ, AND 745 ARTICULATED TRUCKS

Usage:



TEBE7862-04

12Jul2018
(Revised 29Jan2019)


U-404
A-297
D-353
O-364

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION AFTER FAILURE ON CERTAIN 735C, 740C EJ, 745C, 740 EJ, AND 745 ARTICULATED TRUCKS

3030 3160
PS53803
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 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 "PS53803" 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:

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.

 
NOTE:

This Revised Service Letter replaces the 12Jul2018 (Revised 05Dec2018) Service Letter. Changes have been made to the Affected Product, Parts Needed, Action Required, and Rework Procedure.


TERMINATION DATE

31Jul2020

PROBLEM

The existing transmission can generate In Gear Slip Detect codes (IGSD) and may have clutch 4, clutch 6, stub shaft, clutch 1/3 dowels and/or speed sensor related premature failures on certain 735C, 740C EJ, 745C, 740 EJ, and 745 Articulated Trucks.

AFFECTED PRODUCT

Model Identification Number
*******Group  1*******
735C LFJ00252-00254

TFJ00141-00334
740C EJ LFN00272-00278

TFN00161-00202
745C LFK00262-01113

TFK00151-01693
745C OEM JE800101-00116

JE900101-00102
*******Group  2*******
740 EJ 3F700272-00275

3T700161-00174
745 3F600262-01037, 1302

3T600151-01022, 1574-1579

PARTS NEEDED

Qty

Part Number Description
*******Group 1*******
4 0S1604 BOLT
2 1P3704 SEAL-RECTANGULAR
2 1P9216 RING-SEAL
1 1S6515 RING-SEAL
1 1T0234 RING-METAL SEAL
5 1T1597 RING-SEAL
2 1T1599 RING-SEAL
6 2J0157 SEAL-O-RING
1 2S1362 RING-SEAL
1 3D2824 SEAL-O-RING-STOR
2 3H4970 SEAL-O-RING
1 3K0360 SEAL-O-RING
1 3S1279 RING-SEAL
1 4F7389 SEAL-O-RING
4 4J0522 SEAL-O-RING
1 4M0189 SEAL-O RING
1 4M6480 GASKET
1 5P8286 SEAL-O-RING
2 6F0155 RING-METAL SEAL
2 6J2244 SEAL-O-RING
2 6T0248 RING-SEAL
1 6T0838 RING-SEAL
4 6U0455 STRAP
4 6U0456 LASHING TIE 20
1 6V1720 PLATE-SERIAL NO
1 6V3955 SEAL-O-RING
2 6V5141 SEAL-O-RING
1 6V8001 SEAL-O-RING
1 6V8398 SEAL-O-RING-ORFS
2 6Y2983 RING-SEAL
3 7M8485 SEAL-O-RING-STOR
1 7S7018 RING-SEAL METAL
1 7T5987 RING-SEAL
1 7X4744 SEAL-O-RING
1 8L2786 SEAL-O-RING
1 8P8744 RING-SEAL EXT
1 8T2611 RING-RETAINING
1 9G8718 RING-SEAL
1 9H0846 SEAL-O-RING
1 9M2008 RING-METAL SEAL
1 9U9484 RING-SEAL
1 0041964 SEAL-O RING
1 0619457 SEAL-O-RING
1 1073119 SEAL-O-RING
1 1336578 SEAL-O-RING
1 1503296 RING - SEAL
1 1650507 RING-SEAL (EXT)
2 1757904 SEAL-O-RING
4 2284947 SEAL-O-RING
2 2287092 SEAL-O-RING-ORFS
2 2287093 SEAL-O-RING-ORFS
1 2385082 SEAL-O-RING-STOR
3 2385084 SEAL-O-RING-STOR
1 2432737 SEAL-O-RING
1 2696932 BEARING-THRUST
1 3116130 SEAL-O-RING
1 3308197 SEAL-O-RING
1 3375270 ELEMENT AS-XMSN
6 3533952 DISC-FRICTION
6 3534888 PLATE-CLUTCH
56 3534922 BUTTON-THRUST
1 3534938 GASKET
1 3592811 GASKET
1 3592813 GASKET
1 3653179 SEAL-LIP TYPE
1 3679384 SEAL-O-RING
1 3679385 SEAL-O-RING
1 3704648 GASKET
1 3810187 GASKET
1 3853954 GASKET
1 3853955 GASKET
1 3872970 GASKET
1 3872971 GASKET
1 3872973 GASKET
1 4218199 VALVE GP-SOL
1 4255636 GASKET
1 4591195 BEARING-THRUST
1 4666259 RING-RETAINING
1 4677358 PISTON-CLUTCH
2 4780048 RING-SEAL
1 4886382 RING-SEAL
1 4908824 PLATE AS
2 5095767 RING-SEAL
1 5183168 RING-SEAL
7 5185072 VALVE GP-SOL
1 5200122 HUB-CLUTCH
1 5247954 HOUSING-CLUTCH
1 5247955 PISTON-CLUTCH
48 5387564 SCREW-TRUSS HEAD ***
1 5489612 SFWR GP-A4007
1 5489630 SFWR GP-A4015
2 5508164 PIN
1 5523605 SFWR GP-A4017
1 5537191 SHAFT**
1 5567150 SFWR GP-A5007
1 5577681 SFWR GP-A3001
1 5705044 PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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.

*******Group 2*******
4 0S1604 BOLT
2 1P3704 SEAL-RECTANGULAR
2 1P9216 RING-SEAL
1 1S6515 RING-SEAL
1 1T0234 RING-METAL SEAL
5 1T1597 RING-SEAL
2 1T1599 RING-SEAL
6 2J0157 SEAL-O-RING
1 2S1362 RING-SEAL
1 3D2824 SEAL-O-RING-STOR
2 3H4970 SEAL-O-RING
1 3K0360 SEAL-O-RING
1 3S1279 RING-SEAL
1 4F7389 SEAL-O-RING
4 4J0522 SEAL-O-RING
1 4M0189 SEAL-O RING
1 4M6480 GASKET
1 5P8286 SEAL-O-RING
2 6F0155 RING-METAL SEAL
2 6J2244 SEAL-O-RING
2 6T0248 RING-SEAL
1 6T0838 RING-SEAL
4 6U0455 STRAP
4 6U0456 LASHING TIE 20
1 6V1720 PLATE-SERIAL NO
1 6V3955 SEAL-O-RING
2 6V5141 SEAL-O-RING
1 6V8001 SEAL-O-RING
1 6V8398 SEAL-O-RING-ORFS
2 6Y2983 RING-SEAL
3 7M8485 SEAL-O-RING-STOR
1 7S7018 RING-SEAL METAL
1 7T5987 RING-SEAL
1 7X4744 SEAL-O-RING
1 8L2786 SEAL-O-RING
1 8P8744 RING-SEAL EXT
1 8T2611 RING-RETAINING
1 9G8718 RING-SEAL
1 9H0846 SEAL-O-RING
1 9M2008 RING-METAL SEAL
1 9U9484 RING-SEAL
1 0041964 SEAL-O RING
1 0619457 SEAL-O-RING
1 1073119 SEAL-O-RING
1 1336578 SEAL-O-RING
1 1503296 RING - SEAL
1 1650507 RING-SEAL (EXT)
2 1757904 SEAL-O-RING
4 2284947 SEAL-O-RING
2 2287092 SEAL-O-RING-ORFS
2 2287093 SEAL-O-RING-ORFS
1 2385082 SEAL-O-RING-STOR
3 2385084 SEAL-O-RING-STOR
1 2432737 SEAL-O-RING
1 2696932 BEARING-THRUST
1 3116130 SEAL-O-RING
1 3308197 SEAL-O-RING
1 3375270 ELEMENT AS-XMSN
6 3533952 DISC-FRICTION
6 3534888 PLATE-CLUTCH
56 3534922 BUTTON-THRUST
1 3534938 GASKET
1 3592811 GASKET
1 3592813 GASKET
1 3653179 SEAL-LIP TYPE
1 3679384 SEAL-O-RING
1 3679385 SEAL-O-RING
1 3704648 GASKET
1 3810187 GASKET
1 3853954 GASKET
1 3853955 GASKET
1 3872970 GASKET
1 3872971 GASKET
1 3872973 GASKET
1 4218199 VALVE GP-SOL
1 4255636 GASKET
1 4591195 BEARING-THRUST
1 4666259 RING-RETAINING
1 4677358 PISTON-CLUTCH
2 4780048 RING-SEAL
1 4886382 RING-SEAL
1 4908824 PLATE AS
2 5095767 RING-SEAL
1 5183168 RING-SEAL
7 5185072 VALVE GP-SOL
1 5200122 HUB-CLUTCH
1 5247954 HOUSING-CLUTCH
1 5247955 PISTON-CLUTCH
48 5387564 SCREW-TRUSS HEAD ***
2 5508164 PIN
1 5537191 SHAFT**
1 5705044 PLATE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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

Note: Some parts in the 'parts needed' list have been marked with (** or ***) identifiers. Please follow the associated notes, as they may not be needed for most repairs. Only order parts as needed.

** For the 553-7191, order only if you don?t have 471-9315 with EC01 ? see SMAG M0094535. Part number 471-9315 with Engineering Change number of 01 or has a supplier serial number equal to or greater than M446100 has all engineering updates and can still be used.

*** If 538-7564 Screws are not available and are holding up a transmission rebuild, work with your dealer TC to contact product support for alternate assembly instructions.

Note: Verify transmission being repaired is covered under PS53729 Service letter and perform update for intermediate sensors as needed. If the transmission being updated already had PS53729 Service Letter applied, DO NOT update intermediate sensors again.

Refer to SEHS0586, CX38 Transmission Dealer Rebuild Readiness Playbook ? for 735C, 740C, and 745C Articulated Truck.

Refer to SEBF8115, Transmission Clutch Plates and Disc Assemblies with Cellulose Friction Material Reuse And Salvage Guidelines.

Refer to M0072352, CX38 Transmission Pump Inspection Reuse And Salvage Guidelines.

Updating swings is permitted by this letter, but in limited quantities, 5% of fleet to keep parts ordering under control. If reworking a swing that is already tore down the parts list in this letter can be used for updating. Note warranty can?t be charged until the transmission is used in truck, thus up front labor and parts costs are the responsibility of the dealer until the time of install. (Not Parts Stock Action)

If the parts received are damaged, or if you have any questions you will need to work with your Dealer TC to submit the information or question through CPI Feedback within the Service Information Management System (SIMSi).
Give the information to your Dealer Technical Communicator (TC) along with this service letter program number and CPI number 365466.
Request the Dealer TC to submit the CPI Feedback.

Following software called out in the parts list need to be flashed on only C series machines' ECMs to allow proper transmission functionality and to avoid mismatch codes.

Transmission: 556-7150-00 (Available in SIS)
Chassis: 557-7681-00 (Available in SIS)
CMPD: 548-9630-00 (Available in SIS)
Indication Display: 552-3605-00 (Available in SIS)
Payload: 548-9612-00 (Available in SIS)

Note: Flashing the incorrect software other than what is called for will not allow the transmission to shift correctly and could result in damage that will not be covered by warranty.

NOTE: Software updates require the use of Cat ET version 2018A or newer.

Clear all logged and event codes from the transmission ECM. The Transmission Serial Number must be updated on the Trans/Chassis ECM otherwise, the new software will not work correctly. Later add the new serial numbers to SIMSi. Look for more instructions in "ON MACHINE TEST PROCEDURES" section below.

All machines being repaired under this service letter must be documented and summary of completed machines should be sent back to local Caterpillar Representative through email.

After Failure DSN:
Choose "Transmission - Product Health" in the Workgroup / Subsystem field to help expedite the process. Attach the product status reports (PSR) and include all histograms. Attach photos of the machine and transmission serial number plate. Provide a note with details of your preferred repair method. Attach all results of the troubleshooting procedures detailed in the rework procedure. Report resultant damaged parts if they can not be reused or salvaged.

Repair Plan Methods:
Transmission rebuild and bench test facilities are required to perform the Disassembly and Assembly repair of the transmission.

Refer to the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 1*******
0-10000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 85.0-hour job for Group 1

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.

If the transmission being reworked was previously rebuilt, part age/hours will apply instead of machine hours towards the 10000 hour coverage.

Note: If a New or a Reman transmission was approved as the correct repair method instead of dealer rebuild through DSN, claim for one of new or reman unit is allowed and a total of only 60 hours of labor can be claimed. The DSN request number and authorization needs to be listed in the claim when submitted to the warranty system.

Only order parts as needed
** For the 553-7191, order only if you don?t have 471-9315 with EC01 ? see SMAG M0094535. Part number 471-9315 with Engineering Change number of 01 or has a supplier serial number equal to or greater than M446100 has all engineering updates and can still be used.

*** For updating Intermediate sensors. These parts are not required if the transmission being updated already had PS53729 Service Letter applied.

Note: If a transmission repair is performed after failure where bearings and bushings need to be replaced, an additional 15.0 hours of labor can be claimed for completing rebuild and troubleshooting procedures.

Product smu/age whichever comes first
Caterpillar
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
*******Group 2*******
0-10000 hrs,
0-60 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 85.0-hour job for Group 2

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.

If the transmission being reworked was previously rebuilt, part age/hours will apply instead of machine hours towards the 10000 hour coverage.

Note: If a New or a Reman transmission was approved as the correct repair method instead of dealer rebuild through DSN, claim for one of new or reman unit is allowed and a total of only 60 hours of labor can be claimed. The DSN request number and authorization needs to be listed in the claim when submitted to the warranty system.

Only order parts as needed
** For the 553-7191 order only if you don?t have 471-9315 with EC01 ? see SMAG M0094535. Part number 471-9315 with Engineering Change number of 01 or has a supplier serial number equal to or greater than M446100 has all engineering updates and can still be used.

*** For updating Intermediate sensors. These parts are not required if the transmission being updated already had PS53729 Service Letter applied.

Note: This is a total 85.0 hour job to remove and install a transmission from a machine, disassembly and assembly of transmission and to document the repair in SIMS.

Note: If a transmission repair is performed after failure where bearings and bushings need to be replaced, an additional 15.0 hours of labor can be claimed for completing rebuild and troubleshooting procedures.



PARTS DISPOSITION

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


Rework Procedure


 
INVESTIGATION and DIAGNOSTIC TEST PROCEDURES (After Failure repair only)

1. Connect Cat ET (2018A or above) to Download Product Status Report. Make sure that you select the histogram option before creating the report.

2. Review Logged Diagnostic Codes contained in product status report. Refer to UENR2354, 735C, 740C EJECTOR and 745C Articulated Trucks Power Train, Troubleshooting. Follow trouble shooting steps for all active and logged diagnostic codes.

3. Perform the Pump Pressure Test. Refer to UENR4226, Testing and Adjusting, "Power Train Pressures". Refer to Image1.1.1 to log the results.
Image1.1.1
Image1.1.2
 
4. Perform Transmission Clutch Calibration Tests.

The transmission requires two separate calibrations:

1) Engagement Calibration
2) Transmission Fill Calibration, which are both completed through Cat ET.

Test 1:

Perform the Engagement Calibration. Refer to UENR4226, Testing and Adjusting, for Transmission Engage Calibration.

Note: Remove pressure gauges and hoses from transmission pressure ports prior to performing Transmission Fill Calibration procedure.

Test 2:

Perform the Transmission Fill Calibration. Refer to UENR4226, Testing and Adjusting, Transmission Fill Calibration procedure.
 
5. Perform clutch slip test.

Slip Test for clutches (most likely scenarios):

Typically in gear slip detect (IGSD) codes will be logged in more than one gear. To determine if the transmission requires removal, perform specified test for each logged code. Failure of any test will indicate the transmission is damaged. Failure of the test will be indicated by a new logged IGSD code. Test failure may indicate a lack of capacity because of previous slip damage (worn clutch pack) or a damaged seal. The tests are easier to do on the upshifts.

WARNING: For this testing, make sure you have ample room to operate the machine. Ensure the operation is clear from obstacles and personnel as typically done when operating the machine. Using a spotter in the machine with the driver is advised.

In gear slip detect error ? E2201 (Clutch 3, 4 and 6 are active):

Using service brakes and throttle put the truck in 1st gear stall.

Note: If the machine is set to second gear start, this will have to be changed to 1st gear start prior to testing. Refer to SEBU9060, 735C and 745C Articulated Trucks, Operations and Maintenance and refer to SEBU9061, 740C Ejector, Monitoring system - Settings - Machine - Starting Gear. Bring throttle up to full. Hold for at least 15 seconds. Repeat this at least three times. Be aware that the truck most likely will creep forward during this test. Monitor the torque converter temperature during this test as to prevent overheating.

In gear slip detect error ? E2202 (2nd gear slip, Clutch 1 on coming; clutch 3 and 4 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Apply the service brakes and set the transmission into 1st forward.

Note: If the machine is set to second gear start, this will have to be changed to 1st gear start prior to testing. Refer to SEBU9060, 735C and 745C Articulated Trucks, Operations and Maintenance, and SEBU9061, 740C Ejector, Monitoring system - Settings - Machine - Starting Gear. Apply throttle at the same time enough to induce a stall, start slowly letting off on the service brakes to get the machine to upshift into 2nd gear. The brakes are simulating a load on the transmission. If the transmission is going to slip in 2nd gear it will occur just after the shift occurs. Repeat this least three to four times if you are not getting it to slip. Start back in 1st gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to second to occur as the fault locks it out. Restart the truck and attempt to get the slip to at least one more time.
 
In gear slip detect error ? E2202 (2nd gear slip, Clutch 1 on coming; clutch 3 and 4 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Apply the service brakes and set the transmission into 1st forward.

Note: If the machine is set to second gear start, this will have to be changed to 1st gear start prior to testing. Refer to SEBU9060, 735C and 745C Articulated Trucks, Operations and Maintenance, and SEBU9061, 740C Ejector, Monitoring system - Settings - Machine - Starting Gear. Apply throttle at the same time enough to induce a stall, start slowly letting off on the service brakes to get the machine to upshift into 2nd gear. The brakes are simulating a load on the transmission. If the transmission is going to slip in 2nd gear it will occur just after the shift occurs. Repeat this least three to four times if you are not getting it to slip. Start back in 1st gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to second to occur as the fault locks it out. Restart the truck and attempt to get the slip to at least one more time.
 
In gear slip detect error ? E2203 (3rd gear slip, clutch 2 is on coming, clutch 3 and 4 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Get the machine up into 2nd gear and attempt to hold the speed. Start applying the service brakes and throttle concurrently just enough to induce load and allow the shift up into 3rd gear. If the transmission is going to slip in 3rd gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 2nd gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to 3rd to occur as the fault locks it out. Restart the truck and attempt to get the slip at least one more time.
 
In gear slip detect error ? E2204 (4th gear slip, clutches 5 and 6 on coming, clutch 3 is active):

With a warm machine (60 Degrees Celsius), disengage the park brake. Get the machine up into 3rd gear and attempt to hold the speed. Start applying the service brakes and throttle concurrently just enough to induce load and allow the shift up into 4th gear. If the transmission is going to slip in 4th gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 3rd gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to 4th to occur as the fault locks it out. Restart the truck and attempt to get the slip at least one more time.
 
In gear slip detect error ? E2205 (5th gear slip, clutch 1 is on coming, clutch 3 and 5 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Get the machine up into 4th gear and attempt to hold the speed. Start applying the service brakes and throttle concurrently just enough to induce load and allow the shift up into 5th gear. If the transmission is going to slip in 5th gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 4th gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to 5th to occur as the fault locks it out. Restart the truck and attempt to get the slip at least one more time.
 
In gear slip detect error ? E2206 (6th gear slip, clutch 2 is on coming, clutch 3 and 5 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Get the machine up into 5th gear and attempt to hold the speed. Start applying the service brakes and throttle concurrently just enough to induce load and allow the shift up into 6th gear. If the transmission is going to slip in 6th gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 5th gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to 6th to occur as the fault locks it out. Restart the truck and attempt to get the slip at least one more time.

In gear slip detect error ? E2207 (7th gear slip, clutch 1 is on coming, clutch 2 and 5 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Get the machine up into 6th gear and attempt to hold the speed. Start applying the service brakes and throttle concurrently just enough to induce load and allow the shift up into 7th gear. If the transmission is going to slip in 7th gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 6th gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to 7th to occur as the fault locks it out. Restart the truck and attempt to get the slip to at least one more time.
 
In gear slip detect error ? E2208 (8th gear slip, clutch 3 is on coming, clutch 1 and 2 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Get the machine up into 7th gear and attempt to hold the speed. Start applying the service brakes and throttle concurrently just enough to induce load and allow the shift up into 8th gear. If the transmission is going to slip in 8th gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 7th gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to 8th to occur as the fault locks it out. Restart the truck and attempt to get the slip at least one more time.

In gear slip detect error ? E2209 (9th gear slip, clutch 6 is on coming, clutch 2 and 3 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Get the machine up into 8th gear and attempt to hold the speed. Start applying the service brakes and throttle concurrently just enough to induce load and allow the shift up into 9th gear. If the transmission is going to slip in 9th gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 8th gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to 9th to occur as the fault locks it out. Restart the truck and attempt to get the slip at least one more time.
 
In gear slip detect error ? E2301 (Clutch 1, 4 and 6 are active):

Using service brakes and throttle put the truck in 1st reverse gear stall. Bring throttle up to full. Hold for at least 15 seconds. Repeat this at least three times. Be aware that the truck most likely will creep backwards during this test. Monitor the torque converter temperature during this test as to prevent overheating.

In gear slip detect error ? E2302 (2nd Reverse gear slip, clutch 5 is on coming, clutch 1 and 6 are active):

With a warm machine (60 degrees Celsius), disengage the park brake. Apply the service brakes and set the transmission into 1st reverse. Apply throttle at the same time enough to induce a stall, start slowly letting off on the service brakes to get the machine to upshift into 2nd reverse gear. The brakes are simulating a load on the transmission. If the transmission is going to slip in 2nd reverse gear it will occur just after the shift occurs. Repeat this three to four times if you are not getting it to slip. Start back in 1st reverse gear each time. If the slip does occur stop the machine and shut it off, wait until the dash lights go off. This will reset the error condition and allow the shift to second reverse to occur as the fault locks it out. Restart the truck and attempt to get the slip at least one more time.
 
Test sheet for clutch slip:

WARNING: For this testing, make sure you have ample room to operate the machine. Assure the operation is clear from obstacles and personnel as typically done when operating the machine. Using a spotter in the machine with the driver is advised.
Image1.11.1
 
Provide all documentation to the DSN Tier II for review. Additional testing may be recommended, or a service letter repair may be authorized. Do not proceed with transmission removal without DSN authorization.
 
TRANSMISSION REMOVAL


Drain the oil from the transmission system which will include the Torque Converter, transmission and output transfer gear. Refer to 735C and 745C Articulated Trucks Operations and Maintenance Media Number - SEBU9060 and 740C Ejector media number SEBU9061 - "Torque Converter, Transmission, and Transfer Gear Oil - Change".

To remove the transmission refer to: Disassembly and Assembly 735C, 740C EJECTOR and 745C Articulated Trucks Power Train Media Number - UENR4227 Transmission - Remove and Install.
 
DISASSEMBLY AND ASSEMBLY PROCEDURES

Additional information is available for disassembly and assembly of the transmission.

A consolidated guide to rebuild readiness is available in the Shop Review section of SISweb. Refer to CX38 Transmission Dealer Rebuild Readiness Playbook for 735C, 740C, and 745C Articulated Truck Media Number - SEHS0586. The Playbook contains references to tooling lists, training materials, and inspection materials.

For access to a video for this procedure, scan the QR code below with a QR enabled device or copy the link below. If the link doesn't work, copy the entire link and paste in your web browser, make sure there are no gaps or spaces after you paste.

Caterpillar Channel 1 Video: "CX38 Disassembly and Assembly"
Media Number: CATU0825
Channel 1 URL (direct link to video): https://channel1.mediaspace.kaltura.com/media/
CX38+Transmission+Disassembly+and+Assembly/1_hwtr6l0a
Image1.14.1
 
To Remove and Install the Torque Converter refer to: Disassembly and Assembly 735C, 740C EJECTOR and 745C Articulated Trucks Power Train Media Number - UENR4227.

For Disassembly and Assembly the Transmission Planetary refer to 735C, 740C EJECTOR and 745C Articulated Trucks Power Train Media Number - UENR4227.
 
TRANSMISSION BENCH TEST PROCEDURE

When the transmission has been assembled, test the transmission using the test bench procedure. Refer to: Bench Test Procedure for 735C, 740C, and 745C Articulated Truck Transmission. Media Number -REHS9381 - Bench Test Procedure for 735C, 740C, and 745C Articulated Truck Transmission.
 
ENGINE PUMP DRIVE INSPECTION

Engine rear gear train components may be damaged due to lack of lubrication after a transmission failure. Prior to transmission installation, inspect the rear engine gear train gears and bearings for damage. Refer to: Power Take-Off Drive Group section of Disassembly and Assembly C15 and C18 Engines for Caterpillar Built Machines Media Number - UENR0132.

NOTE: O-ring 6V-5141 is included in the R&I Only parts list.
 
TRANSMISSION INSTALLATION

Before installation of the transmission make sure that the transmission system is clean. Refer to Contamination Control Guidelines - SEBF9204 and Cleaning Fluid-Carrying Hose and Tube Assemblies In Shop and Field Applications - SEBF8485.

After transmission installation is complete Fill the transmission with oil. The correct oil level is critical to transmission functionality and on machine test procedures.

Refer to 735C and 745C Articulated Trucks Operations and Maintenance Media Number - SEBU9060 and 740C Ejector media number SEBU9061 - "Torque Converter, Transmission, and Transfer Gear Oil - Change".
 
SERIAL NUMBER PLATE PROCEDURE (Except Reman).

The serial number plate and the stamped serial number on the transmission case must be replaced or reworked to denote that updates have been completed. Remove the original serial number plate from the casing. Replace the serial plate with a new serial number plate.
Image1.19.1
 
Rework the "TRANS SERIAL NO" on the transmission serial number plate from an "M4Y, K38, TJ9, TW5 or TW6" number to a "DW3" number. For a REMAN, MJ8 prefix use the serial number stamped on the outside of the case to create the new serial number.

Note: The last five digits at the end of the "TRANS SERIAL NO" must remain the same.

Rework the "TRANS ARRANG NO" on the transmission serial number plate from the "353-4920", "518-9384", or "20R-6548" or "20R-8342" transmission part number to a "490-8822" part number.


Rework the "CONVERTER SERIAL NO" on the transmission serial number plate to reflect the same number stamped on the original serial number plate.

Clean and prepare the area where the serial number plate will be attached to the transmission case and then apply Loctite 7387 activator.

Apply Loctite 330 adhesive to the back of serial number plate before sticking it to the transmission case.

Note: You may have to hold in position for a short time.

Rework the Transmission Serial Number that is stamped into the transmission case (if applicable) from an "TJ9"(or other serial number prefix) number to a "DW3" number.

Note: The last five digits at the end of the stamped Transmission Serial Number must remain the same. Only change the "TJ9" number.

SERIAL PLATE PROCEDURE (REMAN):

The serial number plate on transmissions with a "Remanufactured Component" serial plate must be replaced.

Locate the original serial number stamped into the transmission case.

Stamp the "TRANS SERIAL NO." with "DW3" followed by the original five digit serial number from the transmission case.

Stamp the "TRANS ARRANG NO" with part number "490-8822".

Stamp the "CONVERTER SERIAL NO." with serial prefix "M7N". A five digit converter serial number is not required.

Clean and prepare the area where the serial number plate will be attached to the transmission case and then apply Loctite 7387 activator.

Apply Loctite 330 adhesive to the back of serial number plate before sticking it to the transmission case.

Note: You may have to hold in position for a short time.

Rework the Transmission Serial Number that is stamped into the transmission case (if applicable) from an "TJ9" number to a "DW3" number.

Note: The last five digits at the end of the stamped Transmission Serial Number must remain the same. Only change the "TJ9" number.

ON MACHINE TEST PROCEDURES.

New needed software details are provided below and under action required sections.

Note: Flashing another software other than what is provided will not allow the transmission to shift correctly and could result in damage that will not be covered by warranty.

NOTE: Software updates require the use of Cat ET version 2018A or newer.

Clear all logged and event codes from the transmission ECM. Transmission Serial Number must be updated on the Trans/Chassis ECM otherwise, the new software will not work correctly. Navigate to Trans/Chassis configuration screen and enter transmission serial number, make sure to use uppercase for letters. Machine may not be allowed to start upon cranking if a valid Trans Serial number is not programmed with correct software. Later add the new serial numbers to SIMSi.

Following software called out in the parts list need to be flashed on only C series machines' ECMs to allow proper transmission functionality and to avoid mismatch codes.

Transmission: 556-7150-00 (Available in SIS)
Chassis: 557-7681-00 (Available in SIS)
CMPD: 548-9630-00 (Available in SIS)
Indication Display: 552-3605-00 (Available in SIS)
Payload: 548-9612-00 (Available in SIS)
 
MAIN TRANSMISSION RELIEF VALVE

Reset the bias compensation for the Main Transmission Relief Valve: Refer to UENR4226 - Testing and Adjusting - Relief Valve (Transmission Main) Pressure - Test - Electronic Main Relief Valve - "Bias Reset".

TRANSMISSION CLUTCH CALIBRATION TESTS

The transmission requires 2 separate calibrations: 1) Engagement Calibration and 2) Transmission Fill Calibration, which are both completed through Cat ET.

Test 1

Perform the Engagement Calibration. Refer to UENR4226 - Testing and Adjusting for Transmission Engage Calibration.

NOTE: Remove pressure gauges and hoses from transmission pressure ports prior to performing Transmission Fill Calibration procedure.

Test 2

Perform the Transmission Fill Calibration. Refer to UENR4226 - Testing and Adjusting Transmission Fill Calibration procedure.

Road test truck by shifting truck up and down thru all forward gears. Also, perform neutral to forward gear and neutral to reverse gear shifts. Ensure all shifts have acceptable shift feel.

After repair is completed update transmission serial number updates in SIMSi.

ADDITIONAL INFORMATION ON MAJOR UPDATES IN PS53803

Clutch 4 Improvements:
Clutch 4 hub (520-0122) has improved lubrication to the clutch. The piston (524-7955) and housing (524-7954) have improve clutch stoke as to not allow the piston to come out of the bore when clutch 4 wears to any great degree which resulted with seal extrusion then loss of pressure.
Image1.21.1
Image1.21.2
 
Clutch 6 Improvements:
Clutch 6 plate assembly (490-8824) now contains an inside diameter seal groove. This requires a new piston seal ? 488-6382. The low gain piston (inner positioned) is now part number 467-7358. The design change allows the piston to come up evenly in the bore of the plate assembly, thus eliminating piston cocking. This led to heavy hot spotting and rough shifts when clutch 6 was activated; mainly forward 3rd to 4th and 8th to 9th. (Note this improvement is already in the 490-8822 production transmissions of the 740 EJ & 745 ATs). For C-Series transmission updates, making this update requires new software to be flashed on the Trans/Chassis which will control the clutch differently during shifts and differences in calibration. Software will be explained further later in this documentation.
Image1.22.1
Image1.22.2
 
Clutch 1/3 Pin Improvements:
The reaction pins in the clutch 1-3 balance piston groups are being updated. The new part number is 550-8164. Two are required per transmission build. This change is also explained with service magazine M0094265. (See pin ? label 1 in the pictures below)

Torque Converter Improvements:
The updated torque converter "L" washer design is intended to provide a better load path through the torque converter retention snap ring. The current design flat washer (370-3812) loads the snap ring with a bending moment that is believed to cause the snap ring to roll out of the mating main shaft groove. The updated "L" washer is design to load the snap ring in a more ideal shear direction that is more resistant to rolling out of the groove. Along with eliminating the bending moment on the snap ring, the "L" washer reduces the stress on the snap ring improving life 6x.
Image1.23.1
Image1.23.2
 
The intermediate speed sensors parts are being improved. Listed in the service letter (PS53803) for convenience, but are covered under service letter PS53729 when worked while the transmission is installed in the truck. The main parts are the following: 546-5409 Sensor Group and 549-7410 Harness. Two of each required for the rebuild. Other parts to go with the sensor changes are seal 3P-0647, 8T-6912 bolt and 354-5137 spacer. Two of each required for the rebuild. This change is also explained with service magazine M0089327.

(1) 546-5409 Speed Sensor Gp
(2) 8T-6912 Bolt
(3) 354-5137 Spacer
(4) 549-7410 Sensor Harness As
Image1.24.1
 
Software update for C-Series to 556-7150 for the xmsn/chassis and chassis to 557-7681. The software update is required due to FILL calibration and clutch control logic for the clutch 6 update. Typically the "entire truck serial number" is entered on the SISWeb screen and the "Service Software Files" screen is selected. The follow screen example will be displayed after the "Flash Files" button is hit:

Update all your software accordingly. Note, the required Chassis software can be downloaded here, but the 556-7150 is not listed, only the type 1 software for the xsmn/chassis. To obtain the 556-7150 you need to be selected individually. See screen shot to follow. With no machine serial number entered go to and the "Service Software Files" screen and select it. Then enter 556-7150 into the Flash Filename name box, then hit enter. The screen will show up. Download the software.
Image1.25.1
Image1.25.2
 
 

Caterpillar Information System:

PRODUCT SUPPORT PROGRAM FOR INSPECTING THE INTAKE AND EXHAUST VALVES ON CERTAIN CATERPILLAR PRODUCTS WITH A C9.3 ENGINE, AND C9.3 GENERATOR SETS, INDUSTRIAL ENGINES, AND MARINE ENGINES PRODUCT SUPPORT PROGRAM FOR INSPECTING THE INTAKE AND EXHAUST VALVES ON CERTAIN CATERPILLAR PRODUCTS WITH A C9.3 ENGINE, AND C9.3 GENERATOR SETS, INDUSTRIAL ENGINES, AND MARINE ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING DRIVELINE BOLTS ON CERTAIN 563D AND 573D WHEEL FELLER BUNCHERS PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING DRIVELINE BOLTS ON CERTAIN 563D AND 573D WHEEL FELLER BUNCHERS
PRODUCT SUPPORT PROGRAM FOR REMOVING THE MLIT EMISSIONS LABEL CERTAIN 226D, AND 232D SKID STEER LOADERS, 239D, AND 249D COMPACT TRACK LOADERS PRODUCT SUPPORT PROGRAM FOR REMOVING THE MLIT EMISSIONS LABEL CERTAIN 226D, AND 232D SKID STEER LOADERS, 239D, AND 249D COMPACT TRACK LOADERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER AND TRANSMISSION FILTER GROUP BYPASS SPOOL ON CERTAIN 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS AT PLANNED COMPONENT REBUILD (PCR) PRODUCT SUPPORT PROGRAM FOR REPLACING THE TORQUE CONVERTER AND TRANSMISSION FILTER GROUP BYPASS SPOOL ON CERTAIN 797, 797B, 797F, AND 797F XQ OFF-HIGHWAY TRUCKS AT PLANNED COMPONENT REBUILD (PCR)
PRODUCT SUPPORT PROGRAM FOR FLASHING NEW SOFTWARE FOR THE DEF PUMP, AND REPLACING THE DEF INJECTOR IF REQUIRED ON CERTAIN TH357D, TH408D, TL1055D, TL1255D, AND TH3510D TELEHANDLERS PRODUCT SUPPORT PROGRAM FOR FLASHING NEW SOFTWARE FOR THE DEF PUMP, AND REPLACING THE DEF INJECTOR IF REQUIRED ON CERTAIN TH357D, TH408D, TL1055D, TL1255D, AND TH3510D TELEHANDLERS
PRODUCT SUPPORT PROGRAM FOR LIFT CYLINDER SHIMS ON CERTAIN 563D, 573D, 2570D, AND 2670D WHEEL FELLER BUNCHERS PRODUCT SUPPORT PROGRAM FOR LIFT CYLINDER SHIMS ON CERTAIN 563D, 573D, 2570D, AND 2670D WHEEL FELLER BUNCHERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE BOLTS THAT RETAIN THE DOZER GROUP PINS ON CERTAIN 824K WHEEL DOZERS AND 826K LANDFILL COMPACTORS PRODUCT SUPPORT PROGRAM FOR REPLACING THE BOLTS THAT RETAIN THE DOZER GROUP PINS ON CERTAIN 824K WHEEL DOZERS AND 826K LANDFILL COMPACTORS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE FRONT OR REAR AXLE PINION ON CERTAIN 980L, 980M, AND 982M WHEEL LOADERS PRODUCT SUPPORT PROGRAM FOR REPLACING THE FRONT OR REAR AXLE PINION ON CERTAIN 980L, 980M, AND 982M WHEEL LOADERS
PRODUCT SUPPORT PROGRAM FOR REPLACING ENGINE CYLINDER BLOCK ON CERTAIN 793D OFF-HIGHWAY TRUCKS PRODUCT SUPPORT PROGRAM FOR REPLACING ENGINE CYLINDER BLOCK ON CERTAIN 793D OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE STICK PIN BORES ON CERTAIN 415F2, 416F2, AND 420F2 BACKHOE LOADERS PRODUCT SUPPORT PROGRAM FOR REWORKING THE STICK PIN BORES ON CERTAIN 415F2, 416F2, AND 420F2 BACKHOE LOADERS
PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793, 793B, 793C, 793D, 797, AND 797B OFF-HIGHWAY TRUCKS, EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES PRODUCT SUPPORT PROGRAM FOR INSTALLING CUFFED CYLINDER SYSTEM COMPONENTS ON CERTAIN 793, 793B, 793C, 793D, 797, AND 797B OFF-HIGHWAY TRUCKS, EQUIPPED WITH 3500 HIGH DISPLACEMENT ENGINES
PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING PHASE 5 SOFTWARE BUNDLE ON CERTAIN 797F OFF-HIGHWAY TRUCKS PRODUCT IMPROVEMENT PROGRAM FOR INSTALLING PHASE 5 SOFTWARE BUNDLE ON CERTAIN 797F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE VALVES ON CERTAIN CATERPILLAR PRODUCTS WITH A C9.3 ENGINE, AND C9.3 GENERATOR SETS, INDUSTRIAL ENGINES, AND MARINE ENGINES PRODUCT SUPPORT PROGRAM FOR REPLACING THE VALVES ON CERTAIN CATERPILLAR PRODUCTS WITH A C9.3 ENGINE, AND C9.3 GENERATOR SETS, INDUSTRIAL ENGINES, AND MARINE ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PARKING BRAKE CONTROL VALVE ON CERTAIN 950L, 950M, 962L, 962M, 966L, 966M, 966M XE, 972L, 972M, AND 972M XE WHEEL LOADERS PRODUCT SUPPORT PROGRAM FOR REPLACING THE PARKING BRAKE CONTROL VALVE ON CERTAIN 950L, 950M, 962L, 962M, 966L, 966M, 966M XE, 972L, 972M, AND 972M XE WHEEL LOADERS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE WIRING HARNESS ON CERTAIN 793D OFF-HIGHWAY TRUCKS PRODUCT SUPPORT PROGRAM FOR REWORKING THE ENGINE WIRING HARNESS ON CERTAIN 793D OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPAIRING CYLINDER HEAD TO BLOCK COOLANT LEAKS ON CERTAIN 797F OFF-HIGHWAY TRUCKS EQUIPPED WITH CERTAIN C175-20 REMAN ENGINES AND REMAN SHORT BLOCKS PRODUCT SUPPORT PROGRAM FOR REPAIRING CYLINDER HEAD TO BLOCK COOLANT LEAKS ON CERTAIN 797F OFF-HIGHWAY TRUCKS EQUIPPED WITH CERTAIN C175-20 REMAN ENGINES AND REMAN SHORT BLOCKS
PRODUCT IMPROVEMENT PROGRAM FOR TIGHTENING THE TORQUE CONVERTER PUMP DRIVE GEAR MOUNTING NUT ON CERTAIN 777G OFF-HIGHWAY TRUCKS PRODUCT IMPROVEMENT PROGRAM FOR TIGHTENING THE TORQUE CONVERTER PUMP DRIVE GEAR MOUNTING NUT ON CERTAIN 777G OFF-HIGHWAY TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SEAT BELT GROUP ON CERTAIN 730, 735, 740, 740 EJ, AND 745 ARTICULATED TRUCKS PRODUCT IMPROVEMENT PROGRAM FOR REPLACING THE SEAT BELT GROUP ON CERTAIN 730, 735, 740, 740 EJ, AND 745 ARTICULATED TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE STEERING SENSOR PIN ON CERTAIN AP1000F, AP600F, AND AP500F ASPHALT PAVERS PRODUCT IMPROVEMENT PROGRAM FOR UPDATING THE STEERING SENSOR PIN ON CERTAIN AP1000F, AP600F, AND AP500F ASPHALT PAVERS
PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN 745 ARTICULATED TRUCKS PRODUCT SUPPORT PROGRAM FOR REPLACING 516-9693 CYLINDER LINERS ON CERTAIN 745 ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR ADDING ENGINE COOLANT ADDITIVE ON CERTAIN 793F, 795F, AND 797F OFF-HIGHWAY TRUCKS EQUIPPED WITH CERTAIN C175-16 AND C175-20 REMAN ENGINES PRODUCT SUPPORT PROGRAM FOR ADDING ENGINE COOLANT ADDITIVE ON CERTAIN 793F, 795F, AND 797F OFF-HIGHWAY TRUCKS EQUIPPED WITH CERTAIN C175-16 AND C175-20 REMAN ENGINES
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 516-9693 CYLINDER LINERS ON CERTAIN 834K WHEEL DOZERS AND 836K LANDFILL COMPACTORS PRODUCT SUPPORT PROGRAM FOR REPLACING THE 516-9693 CYLINDER LINERS ON CERTAIN 834K WHEEL DOZERS AND 836K LANDFILL COMPACTORS
PRODUCT IMPROVEMENT PROGRAM FOR REWORKING 342-7800 AND 20R-0405 ENGINE OIL SCAVENGE PUMPS IN DEALER PARTS STOCK PRODUCT IMPROVEMENT PROGRAM FOR REWORKING 342-7800 AND 20R-0405 ENGINE OIL SCAVENGE PUMPS IN DEALER PARTS STOCK
PRODUCT IMPROVEMENT PROGRAM FOR REPLACING STEERING PIN ON CERTAIN AP300F AND AP355F ASPHALT PAVERS PRODUCT IMPROVEMENT PROGRAM FOR REPLACING STEERING PIN ON CERTAIN AP300F AND AP355F ASPHALT PAVERS
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