PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS Caterpillar


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PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS [UEBE1136]
POWER TRAIN
DIFFERENTIAL & BEVEL GEAR GP
PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS
UEBE1136-01

30Sep2020
(Revised 20Nov2020)


U-572
D-540
O-530

 

After Failure Only

  
  

PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS

3258 3256 3281
PS54443
NOTE:

AVSpare’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 AVSpare.

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 "PS54443" 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 AVSpare product analyst.

 
NOTE:

This Revised Service Letter replaces the 30Sep2020 Service Letter. Changes have been made to the Affected Product and Rework Procedure.


TERMINATION DATE

30Sep2022

PROBLEM

The Differential bearing settings may be incorrect on certain 777E Off-Highway Trucks. This may cause debris in the system or potentially a failure of the differential.

AFFECTED PRODUCT

Model Identification Number
777E KDP00202-00231, 238-296, 298-312, 315-324, 326-328, 332-344, 349-369, 374-383, 386-417, 425-461, 465-470, 472-493, 501-555, 561-564, 567-573, 577-605, 607-633, 638-643, 652-655, 658-688, 691-698, 704-717, 720-770, 772-784, 786-802, 806, 814-858, 864-901, 907-978, 981-1004, 1009-1014, 1020-1086, 1093-1207, 1211-1241, 1243-1425, 1438-1442, 1446-1450, 1452-1480, 1488-1521, 1525-1539, 1541-1578

KDZ00201-00369, 371-387

KYD00101-00102

PARTS NEEDED

Qty

Part Number Description
1 1B6577 BEARING-CONE
1 1M6573 BEARING-CUP
1 2D6506 SEAL-O-RING
1 2D8364 SEAL-O-RING
1 2D9457 BEARING-CONE
1 2H3932 SEAL-O RING
1 2J2152 BEARING-CUP
14 2K0337 LOCKNUT
4 3D5692 BUSHING
1 3D9552 RING-ADJUSTING
4 4D7536 LOCK-NUT
1 4F2041 BEARING-CUP
1 5D7449 BEARING-CUP
1 5D7453 BEARING-CONE
4 5P8245 WASHER-HARD
16 5P8247 WASHER-HARD
2 6K7917 BOLT-LOCKING
1 7D3029 PIN
1 7S8554 SEAL-O RING
8 8T0656 BOLT
1 8W3064 RING-ADJUSTING
1 9M2744 BEARING-CONE
1 9M5874 SHIM-PACK
1 9X7395 SEAL AS
10 1128223 SHIM
10 1128224 SHIM
8 3389622 BOLT-D SHAPED HD
1 3836807 GEAR ST-BEVEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% 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

Refer to the Service Manual if/as necessary and see the attached Rework Procedure.

SERVICE CLAIM ALLOWANCES

Product smu/age whichever comes first
AVSpare
Dealer Suggested
Customer Suggested
Parts %
Labor Hrs%
Parts %
Labor Hrs%
Parts %
Labor Hrs%
0-12000 hrs,
0-24 mo 
100.0%
100.0%
0.0%
0.0%
0.0%
0.0%
 NOTE: This is a 34.0-hour job



PARTS DISPOSITION

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


Rework Procedure


 
After Failure Criteria:

Typical sign of a failed power train include noise or an unusual sound in the rear end, operational complaints, or elevated SOS results.

1. If a failure is suspected, inspect all final drive and differential drain plugs for debris
2. Check SOS (debris over 9 microns may not be picked up with standard SOS, check the ISO)
3. Inspect drained oil for debris

For determining if the differential may have failed:
1) If debris from the magnetic plugs is more prominent on one final drive than the other, that is usually a sign of a failed final drive. There may be some debris on the differential plug but not as much as the final drive plug.
2) If debris from the magnetic plugs is more prominent on the differential plug but there are some on the final drive plugs, that could mean a failed differential.
 
If a rebuild or rework is determined to be needed, please inspect the 107-2958 Nut within the differential group for proper torque (70 +/- 15 Nm or 52 +/- 11 lb ft). If any Nuts are found out of specifications, please enter in a DSN to report this. It could be another failure mode.
Image1.2.1
 
 

Information System:

PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING TRANSMISSION CLUTCH CONTROL VALVES ON CERTAIN 735C, 740, 740 EJ, 745, AND 745C ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING TRANSMISSION CLUTCH CONTROL VALVES ON CERTAIN 740 AND 745 ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE MATERIAL FEED PLANETARY DRIVES ON CERTAIN AP500F, AP555F, AP600F, AP655F, AP1000F, AND AP1055F ASPHALT PAVERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE ENGINE OIL SCAVENGE PUMP BOLTS ON CERTAIN 797F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE PRODUCT LINK HARDWARE ON CERTAIN 18 MOTOR GRADERS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE WATER PUMP ON CERTAIN 745 ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR INSTALLING A NEW HOSE AND MOUNTING BRACKET FOR THE AIR LINES GROUP ON CERTAIN 815K AND 816K LANDFILL COMPACTORS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE HINGE ASSEMBLIES ON CERTAIN 140GC MOTOR GRADER.
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING CERTAIN REMAN CYLINDER PACKS SHORT BLOCKS IN DEALER PART STOCK
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING, REWORKING, AND POSSIBLY REPLACING THE PUMP ELECTRONIC TANK UNIT (PETU) HARNESS AND MAIN POWER RELAY ON CERTAIN 785G, 789G, 793F, 794 AC, 797F, AND 798 AC OFF-HIGHWAY TRUCKS, AND 994K WHEEL LOADERS
PRODUCT SUPPORT PROGRAM FOR INSTALLING NEW AIR FILTER COVERS AND CLIPS ON CERTAIN 795F AC OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE YOKE ON CERTAIN CS54B AND CP54B VIBRATORY SOIL COMPACTORS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE HANDLE ASSEMBLY IN THE CAB LEFT HAND SIDE DOOR GROUP ON CERTAIN 773E AND 777E OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE 262-9948 BOLTS AND 476-7141 HOUSING ASSEMBLY USED IN THE PLANETARY ON CERTAIN R1700 LOAD-HAUL DUMP MACHINES
PRODUCT SUPPORT PROGRAM FOR REPLACING REAR SPINDLES AT PCR ON CERTAIN 777F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR INSPECTING AND REPLACING CLUTCH HOUSINGS ON CERTAIN 793F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR INSTALLING ADDITIONAL BOLTS TO THE TOW ARM AND DROP ARM JOINT FOR CERTAIN AP655F ASPHALT PAVERS EQUIPPED WITH SE60 V XW AND SE60 VT XW SCREEDS
PRODUCT SUPPORT PROGRAM FOR REWORKING THE TRANSMISSION ON CERTAIN 745 AND 745C ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE WHEEL (HUB) ON CERTAIN 745C ARTICULATED TRUCKS
PRODUCT SUPPORT PROGRAM FOR RELOCATING THE THERMOSTATIC CONTROL MODULE ON CERTAIN 797F OFF-HIGHWAY TRUCKS
PRODUCT SUPPORT PROGRAM FOR REPLACING THE RADIATOR ON CERTAIN 793D OFF-HIGHWAY TRUCKS
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING 583-6638 GRADER BLADE WING KITS IN DEALER PARTS STOCK
PRODUCT IMPROVEMENT PROGRAM FOR REROUTING THE HOSE ASSEMBLY FROM TOP OF THE CHARGE PUMP ON CERTAIN 259D3 COMPACT TRACK LOADERS AND 236D3/242D3 SKID STEER LOADERS