COVER 4530661 - Caterpillar

Illustration 12 g02515477
The illustration shows locations of the bolts and the idler shafts of the rear gear trains for 3512 and 3516 Engines. (3) Idler Gear Shaft (9) Bolt. (8) Idler ShaftEarlier rear gear trains used 1/2-13 1A-5822 Bolts which were tightened to 135 15 N m (100.0 11.0 lb ft).Current rear gear trains use 5/8-11 1B-4367 Bolts which are tightened to 240 20 N m (176.0 15.0 lb ft). These bolts are used in newer models, or rear groups which were salvaged by tapping the holes to 5/8-11.Note: Add this new information on bolt tightening to the module for specifications and the module for Disassembly and Assembly in the appropriate Service Manuals.Reworking Idler and Cluster Gear Shafts
This procedure is for reworking idler gear shaft (9) and the shaft of the cluster gear (8). If the original shafts ( 1N-4054 Idler Shaft , 4W-4998 Gear Shaft , or 4W-5014 Idler Shaft ) are used again, then the shafts must be reworked in order to provide a second oil hole. This oil hole is made by extending the current oil hole through to the other side of the shaft.The oil hole of the shaft can be drilled on a small drill press. The shaft must be clamped in a vise. The speed of the spindle should be approximately 440 rpm. Illustrations 13 and 14 show the new style of shafts which have through oil holes. Use the following procedure to add the second oil hole.
Illustration 13 g01477940
The new idler shaft is shown on the left. The old idler shaft is shown on the right.
Illustration 14 g01477942
The new shaft of the cluster gear is shown on the left. The old shaft of the cluster gear is shown on the right.
Clamp the shaft in a vise.Note: Do not use a solid carbide drill bit.
Use the existing oil hole as a pilot to drill the new oil hole. Use a 5.94 mm (0.234 inch) carbide tipped drill bit, and drill approximately 1.5 mm (0.06 inch) into the shaft.
Remove the carbide drill bit, and change to a 5.94 mm (0.234 inch) cobalt drill bit. Drill through the shaft. Use liberal amounts of cutting fluid to cool the drill bit.
Chamfer the oil hole with a carbide burr in order to remove any burrs. If burrs are not removed, then burrs can damage the sleeve bearings.Sleeve Installation and Machining Procedure
All Camshaft Idler Gear and Cluster Gear Assemblies
When sleeve bearings are replaced, use the installation and the removal procedure in the Service Manual. The same procedure is used for the removal of the bearings for both the former style and the new style. Former idler gears and idler shafts CANNOT be mixed with new idler gear assemblies and idler shafts. If a new idler gear assembly is used, then the assembly should be installed with a new idler shaft.
During the reconditioning of the cluster gear assembly (15), install the sleeve bearing (12) into the gear (15) to the depth (B). During reconditioning of