POWER SOCKET 4C9917 - Caterpillar

Problem
The 7U6042 Gear Case, which is part of the 7U6050 Transfer Gear Group (Splitter Box) may fail on certain D350D and D400D Articulated Dump Trucks. The case can be replaced with an improved 7U7490 Gear Case.
Affected Product
Model & Identification Number
D350D (9RF39-269)
D400D (8TF35-229; 4EJ1-14)
Parts Needed
2 5P1086 Seal1 5P7032 Seal2 2U1574 Seal1 2U5351 Seal2 7U3263 Seal1 7U7490 Gear CaseAction Required
See attached procedure.
Service Claim Allowances
This is a 20-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
(1-Rework Procedure)Rework Procedure
1. Drain the transfer gearbox.2. Turn the steering to full left lock. Stop the engine and put a "Do Not Operate" sign on the start controls.3. Relieve drive line torque wind up (see procedure in the Service Manual) and remove the center drive shaft.Refer to Illustration 1 for the following steps.
Illustration 14. Remove the six bolts securing the 7U4167 Bearing Carrier (33) to the front of the hitch tube and remove the carrier complete with yoke and bearing.5. Withdraw the 7U3265 Through Hitch Drive Shaft until it disengages the splines at the transfer gearbox end.6. Disconnect the breather hose from the transfer gearbox.7. Remove the two drive shafts connecting the 6WD transfer gearbox to the mid bearing and center axle differential input yoke.8. Remove the 9F6936 Bolt (7) and 2U2502 Nut (3) securing the 7U2787 Torque Rod to the rear frame.9. Remove the locking plate (16) and the ring of eleven 1D4719 Nuts (8) securing the 7U5730 Bearing Carrier (15) to the hitch tube.10. Install tool 4C4174 on the transfer gearbox and use a suitable wheeled jack to support the weight of the assembly.11. Remove the transfer gearbox complete with rear bearing carrier and bearings. If the rear bearing carrier is tight, removal may be difficult. Tightening the hitch thrust flange against the rear bush can help to jack the carrier out. Keeping the transfer drive as square as possible also helps. If the carrier is tight, strong leverage may be necessary to disengage it from the hitch tube. When jacking out the carrier by tightening the thrust flange, turn the thrust flange back before it comes off the carrier and insert packers between the flange and the hitch bush. This will allow further jacking out by tightening the thrust flange.
12. Thoroughly clean the outside of the transfer gearbox and remove the 7U3262 Yokes.Refer to Illustration 2 for the following steps
13. Remove the two 7U3264 Bearing Carriers (16), complete with bearings, and completely withdraw the top and bottom gear and bearing assemblies.14. Remove the 7U3540 Retaining Plate (24), 7U3539 Snap Ring (23), and withdraw the 7U3260 Idler Gear Pin (21), leaving the idler gear and bearing assembly in the case.15. Lift out the idler gear and bearing assembly. Be particularly careful to recover 7U3261 Thrust Washer (22).16. Inspect all parts and replace any which are worn or damaged.17. Inspect the new 7U7490 Gear Case to ensure that it is completely free from debris.18. Install a new 5P7032 Seal (1) in the transfer gear case.19. Smear 7U3261 Thrust Washer