KIT-COUPLER 4557380 - Caterpillar

Problem
The 7N7999 Cylinder Head Gasket may fail on certain D6D, D6H, D7G, And D7H Tractors; 12G, 14G, And 140G Motor Graders; D25C, D25D, D30C, D30D, D35C, D250B, D300B, D350C, And D350D Articulated Dump Trucks; Challenger 65 Tractors; 235C Excavators; 528 Skidders; 615C, 627E, And 637E Scrapers; 815B And 816B Compactors; 966D And 966E Loaders; And 973 Loaders allowing compression to leak by the combustion seal either externally or into the cooling system.
Affected Product
Model & Identification Number
D6D (6HC1-1967)
D6H (4RC1-2518; 8FC1-1029; 5HF1-369; 6CF1-584; 3ZF1-1222; 2TG1-515; 3YG1-522; 4LG1-864; 1FJ1-476)
D7G (65V1-7294)
D7H (5BF1-856; 79Z1-2324; 80Z1-803)
12G (3WC1-1333; 61M1-13494)
14G (03L1-212; 96U1-7824)
140G (72V1-12582; 13W1-775)
D25C (9YC1-1011)
D25D (1HK1-185)
D30C (7ZC1-257)
D30D (3AJ1-128)
D35C (2GD1-124)
D250B (5WD1-399)
D300B (4SD1-481)
D350C (8XC1-404)
D350D (9RF1-162)
CH65 (7YC1-1557)
235C (5AF1-858; 2PG1-558; 3WG1-184; 4DG1-430)
528 (96C1-720; 97C1-375)
615C (5TF1-327)
627E (6EB1-649; 6FB1-613; 6GB1-776; 6HB1-776)
637E (1FB1-400; 1HB1-456; 1JB1-695)
815B (17Z1-1121)
816B (15Z1-981)
966D/E (7BB101-199; 94X6489-9030; 99Y5315-6954)
973 (86G1-1031)
Parts Needed
*1 - Gasket Kit (Use appropriate gasket kit) **1 - 9L5855 Insert (.030)or9L5856 Insert (.035)or9L5857 Insert (.040)or9L5858 Insert (.045)1 - 4M2969 Gasket-Oil Pan ***1 - 2P8889 Liner **3 - 5S6670 Seal **1 - 2W6134 Band*Part number varies by application. See the parts book microfiche and choose the appropriate gasket kit. Make sure that the gasket kit contains the 7E6167 Cylinder Head Gasket. See the June 7, 1990 Service Letter PI7237.**Quantity listed is per cylinder.***Use as required if replacement is needed.Action Required
After a cylinder head gasket fails, check the fuel settings for probable contribution to the gasket failure. If the engine is found to have been adjusted in excess of specification, this Program cannot be applied.
Follow the procedures in the Service Manual to make the necessary repairs using a new 7E6176 Cylinder Head Gasket. The repairs will include lifting the cylinder packs and inspecting for wear/erosion under the liner flanges. Where measurable wear or erosion exists on the cylinder block top deck, make a repair using stainless steel inserts and possibly a new liner. See Special Instruction FMO55228 to install the inserts. Use only stainless steel inserts. If the bottom surface of the cylinder head is damaged, repair by resurfacing or use a Remanufactured cylinder head. The spacer plate should also be inspected for erosion and warpage. Liner projection measurements should be recorded in the dealer service report for reference.
When installing the cylinder head, make sure the head bolts and washers are coated with 6V4876 Molykote.
Refer to the following articles:Service Magazine, November 19, 1990 "New Head Gasket Used On 3306B Truck Engines"
Service Claim Allowances
This is a 18-hour job.
An additional 1-hour of labor per cylinder may be claimed if installation of a block insert is necessary.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.