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 [UEBE1135]
POWER TRAIN
DIFFERENTIAL & BEVEL GEAR GP
PRODUCT SUPPORT PROGRAM FOR REBUILDING THE DIFFERENTIAL ON 777E OFF-HIGHWAY TRUCKS
UEBE1135-00

30Sep2020


O-531

 

Before/After

  
  

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

3258 3256 3281
PS46871
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 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 "PS46871" 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.

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.


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  KDP00232-00237, 297, 313-314, 325, 329-331, 345-348, 370-373, 384-385, 418-424, 462-464, 471, 494-500, 556-560, 565-566, 574-576, 606, 634-637, 644-651, 656-657, 689-690, 699-703, 718-719, 771, 785, 803-805, 807-813, 859-863, 902-906, 979-980, 1005-1008, 1015-1019, 1087-1092, 1208-1210, 1242, 1426-1437, 1443-1445, 1451, 1481-1487, 1522-1524, 1540, 1579

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 (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% 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


 
There should be one swing Differential & Bevel Gear Group available to swap into a machine.

1. Inspect drain plugs for debris
.. a. Final Drive
.. b. Differential
2. Check SOS
3. Inspect drained oil for debris
4. Ship 1 CRC (Component Rebuild Center) rebuilt {per current D&A} Differential & Bevel group to specified 777E Off-Highway Truck
5. Swap CRC rebuilt group out with the machine Differential & Bevel Gear Group.
6. Send machine Differential & Bevel Gear Grp to the CRC for rebuild
7. Keep this process going until all 777E Off-Highway Trucks are updated

(CRC) Component Rebuild Center

104-9410 Differential & Bevel Gear Groups need to be checked and have proper bearing setting and backlash.

505-5921 and 346-2106 Differential Groups need to make sure each of the 107-2958 Nuts are secured at proper torque with at least one tab sticking up for each of the 4D-7536 Locknut.

Follow UENR7316 for differential removal, installation, and for rebuild purposes.


1. Replace all Bearings
.. a. 2D-9457 - Cone
.. b. 4F-2041 - Cup
.. c. 1B-6577 - Cone
.. d. 2J-2152 ? Cup
.. e. 5D-7453 ? Cone
.. f. 5D-7449 ? Cup
.. g. 9M-2744 ? Cone
.. h. 1M-6573 - Cup
2. Replace Differential Housing Bolts
.. a. 505-5921 Grp (shown) = eight (8) 8T-0656 Bolts
.. b. KDP00001-00206 - 346-2106 grp = eight (8) 338-9622 Bolts and eight (8) 2K-0337 Locknuts
Image1.1.1
 
3. Inspect for proper torque (70 +/- 15 Nm or 52 +/- 11 lb ft) of the 107-2958 Nut within the differential group
.. a. Flip lock washer tab up
.. .. i. Flip 2 or more up to corresponding flat surfaces
Image1.2.1
 
 

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