0202103 EVINRUDE PLUG, Expansion

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
This Program can only be administered after a failure occurs. The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS5228" as the Part Number and "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the January 31, 1997 (Revised December 1997) Service Letter. Changes have been made to the TERMINATION DATE and Affected Product.
Termination Date
June 30, 1999Problem
Oil may leak out of the exhaust manifold joints on the 3406E Truck Engines.
This service letter must be completed before any internal repairs can be completed.
Affected Product
Model & Identification Number
3406E (5EK1-Up 6TS1-Up 4AS1-Up )
Parts Needed
1 - 1326660 Joint KitAction Required
See the attached rework procedure.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.(1-Rework Procedure)Rework Procedure
1. Clean the exhaust manifold area (high pressure wash) prior to installing the exhaust manifold slip-joint shields.2. Install one exhaust manifold slip-joint shield retaining clamp loosely around the manifold slip-joint and move it aside temporarily.3. Take the packing material, noting that the thick section of the material goes over the male section of the manifold and that the center stair-step shoulder of the packing will position tightly against the female end of the manifold. (See Illustration 1)4. Wrap the packing material tightly around the slip-joint and place the overlapping ends near the top of the manifold. If need be, the packing material can be stretched to obtain an overlapping joint. Make sure the stair-step shoulder of the packing material is held tightly against the female end of the manifold.5. Install the shield lower half (short one without the extensions) over the packing material with the shield parting line in the horizontal position. The deep flange of the shield is installed over the thick section of the packing material over the manifold male end.6. Install the upper half of the shield over the packing material with the extensions of the shield facing downward. Make sure that the shield top half overlaps the shield lower half when the clamps are tightened. A butt joint between the two halves of the shield will prevent sufficient compression of the packing material and may result in a leaking joint. (See Illustration 2)7. With the shield properly centered over the packing material, slide the loosely installed clamp over the shield assembly and lightly tighten the clamp to hold the shield in place. Install a second clamp between the shield dimples and lightly tighten the clamp. The clamps worm drives must be staggered to allow both clamps to fit between the dimples. Tighten both clamps bolts alternately, with a torque wrench, to a final torque of 14 1 N m (120 10 in lbs).Proper torque is necessary for the compression of the packing material to prevent oil leaks.8. Repeat Steps 2 through 7 for the installation of the other exhaust manifold slip-joint shield. The customer MUST be informed to bring the truck back to any dealer repair facility if exhaust smoke is visible and/or oily odors can be detected as a result of an exhaust manifold slip-joint leak. If this happens, review Step 6 to make sure that the joint between the top and bottom shield overlaps.
Illustration 1
Illustration 2