545554 Force GEAR HOUSING UPPER

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 "PS5412" 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 April 7, 1998 Service Letter. Changes have been made to the TERMINATION DATE.
Termination Date
March 31, 2000Problem
The water cooled manifolds are failing due to acid attack in the weld seam where the stainless steel end cap is welded to the carbon steel tube. This results in corrosion and ultimately creates a pin hole size coolant leak into the exhaust stream.
Affected Product
Model & Identification Number
G3508 (2JF178, 2JF182, 2JF193, 2JF257, 2JF264, 2JF275 9TG16 , 9TG27)
G3512 (4KC276, 4KC287, 4KC315, 4KC335, 4KC340, 4KC408, 4KC455, 4KC459, 4KC464, 4KC491 5JD17 , 5JD18 7NJ23 , 7NJ27, 7NJ64, 7NJ65, 7NJ68, 7NJ74, 7NJ144)
G3516 (3RC73, 3RC97-101, 3RC103-105, 3RC146, 3RC147, 3RC273-275, 3RC278, 3RC302, 3RC306 , 3RC326, 3RC336-339, 3RC346-349, 3RC351, 3RC367, 3RC374, 3RC375, 3RC384 , 3RC386, 3RC388-390, 3RC392, 3RC393, 3RC416, 3RC417, 3RC419, 3RC420, 3RC430 , 3RC435, 3RC437, 3RC440, 3RC447, 3RC455, 3RC458, 3RC464, 3RC466-468, 3RC473 , 3RC486, 3RC494, 3RC496, 3RC507, 3RC509, 3RC510, 3RC514, 3RC516, 3RC547, 3RC555 , 3RC557, 3RC558, 3RC625, 3RC626, 3RC635, 3RC639-641, 3RC655, 3RC658-666 , 3RC714, 3RC743, 3RC786, 3RC790, 3RC811, 3RC812, 3RC815, 3RC818-821 , 3RC823, 3RC889, 3RC894-896, 3RC898, 3RC899, 3RC901, 3RC902, 3RC904 , 3RC905 4EK29-31 , 4EK34, 4EK87, 4EK88, 4EK111, 4EK112, 4EK114, 4EK116, 4EK117, 4EK123, 4EK124 , 4EK126-136, 4EK141, 4EK142, 4EK145, 4EK147, 4EK161, 4EK165, 4EK167, 4EK170-175 , 4EK177-181, 4EK185, 4EK186, 4EK203, 4EK205-208, 4EK211, 4EK212 , 4EK215-220, 4EK234, 4EK235, 4EK265, 4EK266, 4EK270, 4EK272, 4EK274, 4EK276 , 4EK280, 4EK282, 4EK283, 4EK289-299, 4EK329, 4EK334, 4EK344, 4EK347, 4EK348 , 4EK353-356, 4EK358, 4EK368, 4EK370-379, 4EK382, 4EK383, 4EK386, 4EK390 , 4EK392, 4EK413-415, 4EK419, 4EK422, 4EK424, 4EK430, 4EK435, 4EK437, 4EK459 , 4EK460, 4EK462, 4EK464-472, 4EK522-527, 4EK533, 4EK537, 4EK540, 4EK545 , 4EK555-557, 4EK575, 4EK577-580, 4EK584, 4EK585, 4EK589, 4EK591-593 , 4EK609, 4EK610, 4EK621, 4EK634, 4EK635, 4EK637-639, 4EK649, 4EK655 , 4EK661, 4EK663, 4EK664, 4EK666, 4EK688, 4EK694, 4EK695, 4EK699, 4EK723 , 4EK724, 4EK726, 4EK727, 4EK752, 4EK754, 4EK759, 4EK760, 4EK771, 4EK772, 4EK792 , 4EK794, 4EK800, 4EK801, 4EK811, 4EK835, 4EK836, 4EK838, 4EK891, 4EK893, 4EK947-950 , 4EK952, 4EK953, 4EK956, 4EK960, 4EK962, 4EK963, 4EK968, 4EK969, 4EK1052 , 4EK1055, 4EK1065, 4EK1066, 4EK1069, 4EK1070, 4EK1081, 4EK1118, 4EK1120 , 4EK1123-1132, 4EK1142, 4EK1192-1197, 4EK1244, 4EK1245, 4EK1279 , 4EK1280, 4EK1298, 4EK1299, 4EK1322-1326, 4EK1360, 4EK1362, 4EK1366 , 4EK1368-1370, 4EK1373, 4EK1378, 4EK1418, 4EK1419, 4EK1469, 4EK1496 , 4EK1498-1500, 4EK1502, 4EK1537, 4EK1538, 4EK1543, 4EK1546, 4EK1551 , 4EK1552, 4EK1555, 4EK1557-1563, 4EK1565, 4EK1568-1570, 4EK1572-1575 , 4EK1579, 4EK1581, 4EK1582, 4EK1585, 4EK1590, 4EK1591, 4EK1597 , 4EK1601, 4EK1605, 4EK1613, 4EK1620, 4EK1628, 4EK1636, 4EK1647, 4EK1650 , 4EK1652, 4EK1655, 4EK1669, 4EK1674, 4EK1676, 4EK1693, 4EK1701, 4EK1710 , 4EK1711, 4EK1728)
Parts Needed
1 - 1096795 Manifold Assembly (For G3508)1 - 1096797 Manifold Assembly (For G3508)1 - 1096794 Manifold Assembly (For G3512)1 - 1096796 Manifold Assembly (For G3512)1 - 1086175 Manifold Assembly (For G3516)1 - 1086176 Manifold Assembly (For G3516)Action Required
Replace the failed exhaust manifold with a new exhaust manifold.
Service Claim Allowances
This is a 5-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.