EXHAUST- 4C9920 - Caterpillar

Problem
The axle differential thrust washers may fail and/or the bevel gear bolts may loosen on certain D25D, D30D, D350D, and D400D Articulated Dump Trucks.
Affected Product
Model & Identification Number
D25D (1HK1-291)
D30D (3AJ1-304; 1PK1-33)
D350D (9RF1-357)
D400D (8TF1-391; 4EJ1-19)
Parts Needed
Quantities listed are per axle.
Tractor Axle D400D (Bevel gear bolts do not need to be replaced)
1 - 3J0634 Seal1 - 5M7329 Seal-O-Ring4 - 4V5397 WasherTrailer axle D400D, or any axle of D25D, D30D, or D350D
1 - 4H6520 Seal1 - 3K1852 Seal24 - 5P8245 Washer24 - 8T0799 Bolt4 - 4V5397 WasherAction Required
All Axles
Remove the axle differentials from the affected product.
Disassemble the differentials and replace the existing 4V5397 Washers with new washers of the same part number.
Before assembling the differential case, check the washers to insure there is a minimum of (.020") end play between the washers and the differential case assembly. If the end play is between (.00" and .020"), grind the 4V5392 Spiders at the shoulders to provide the necessary clearance for the washers.
Trailer Differential On D400D And All Differentials On D25D, D30D, And D350D
Replace the 8T0799 Bolts securing the 9C8205 Bevel Gear to the 9C9772 Differential Group. Tighten the bolts evenly in sequence order to a torque of 50 to 80 N m (38 to 58 lb ft). Then, tighten the bolts an additional 110 to 130 Degrees in the same order.
Refer to the Systems Operation Testing and Adjusting portion of the Service Manual for the bearing and backlash adjustment procedures.
Complete the assembly and installation of the differentials.
Fill the axles with lubricating oil.
Service Claim Allowances
This is a 46-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.