SHAFT GP-DRIVE 8X0249 - Caterpillar

This is a 3.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
BEFORE COMPLETING THIS REWORK PROCEDURE:
Note: Read all provided instructions prior to beginning the Service Letter Rework Procedure. The procedure requires the use of a micrometer for measuring the shim pack and a 50-75mm (or 2-3 in) O.D. micrometer for yoke measurement. Refer to UENR0281, "Disassembly and Assembly", for additional information.
Experience has shown that on a cold machine there is minimal fluid loss during the rework procedure. Some oil can be drained from these components in order to completely eliminate the possibility of oil spillage/loss.
Park machine on level ground, engage the parking brake, lower the bucket to the ground, install the articulation lock, and shut the machine down. Release trapped cylinder pressure by turning the key to the ON position and cycling all controls.
1. Remove the rear drive shaft guard, if equipped. Remove the existing 346-8616 Rear Driveshaft. The 346-8616 Rear Driveshaft will not be reused. The existing 4E-5986 Straps and 4E-5985 Bolts will not be reused. Refer to UENR0281, Disassembly and Assembly, drive shaft removal procedure rear drive shaft. Refer to Image1.1.1
Image1.1.1
2. Remove the existing 357-0596 Transmission Yoke. The yoke will not be reused. Use the existing 7G-5220 Retainer, 4F-8824 O-ring, and 6V-7673 M12 Bolt. Install the new 357-0597 Yoke. Tighten to a specified torque of 120 +/- 20 N.m. Refer to Image1.2.1.
Image1.2.1
3. Remove the existing 203-2759 Yoke from the rear axle and thoroughly clean the surfaces.
Note: Do not strike the yoke or pinion shaft with a hammer. Remove and retain the entire 9U-3409 Shim Pack. Refer to Image1.3.1.
4. Measure the stand height of the existing yoke with a 50-75mm O.D. micrometer. Refer to image. Repeat the measurement on the opposite side of the yoke. Calculate the average of the two measurements and document as "D". Measure the stand height of the new yoke with a 50-75mm O.D. micrometer. Refer to image. Repeat the measurement on the opposite side of the yoke. Calculate the average of the two measurements and document as "E".
Using the following equation, B = E-D , Calculate "B" referred to as the yoke delta. If "B" is a negative number, carry the (-) sign. Refer to Image1.3.2 for the yoke measurement.
5. Remove oil and debris from the existing 9U-3409 Shim Pack and measure the shim thickness with a micrometer and document the value as "A". Refer to image. Refer to Image 1.3.3 and calculate the new shim pack thickness for the new yoke by using the following equation:
New shim = A+B-C (where C always is 0.001in or 0.025mm
Example:
A (original shim thickness) is 0.081in
B (yoke delta) is -0.002in
C (constant) is 0.001in
New shim = A + B - C
New shim = 0.081 + (-0.002) - 0.001
New shim = 0.078in
6. Rearrange the new calculated shim pack by positioning the thinnest shims between the thickest shims in order to prevent shim damage during tightening. Install new 203-2764 Axle Yoke and calculated new 9U-3409 Shim Pack. Reuse the 9V-2412 Retainer, 2H-3927