90301-ZY6-000 Honda NUT, CLIP (Honda Code 7636301).

12Mar2009
U-103
A-91
D-87
O-89
Safety
Parts stock action needed PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REPLACING THE FRONT ENGINE STEP ON CERTAIN REMANUFACTURED 3524 ENGINES INSTALLED IN 797 AND 797B OFF-HIGHWAY TRUCKS
7254 PI10745
This Program must be administered as soon as possible.When reporting the repair, use "PI10745" as the Part Number and "7751" as the Group Number, "56" as the Warranty ClaimDescription Code and "T" as the SIMS Description Code.
Exception: If the repair is done after failure, use "PI10745" as the Part Number, "7751" as the Group Number,"96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
PROBLEM
The existing front engine step can fail at a welded joint on certain remanufactured 3524 engines installed in 797 and 797B Off-Highway trucks. Standing on a step with a failed welded joint may present a risk of personal injury or death.
AFFECTED PRODUCT
Model Identification Number
797 5YW00193-00277
797B JSM00123-00443
PARTS NEEDED
Qty
Part Number Description
1 1864200 STEP AS
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 40% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
****Parts Stock ****
1. Inspect the 3524 engines in dealer parts stock to determine if they are equipped with a 186-4200 change level 00 step. Refer to Image2 - Image4 in the Action Required.
- If the step is as shown in Image 3, no further rework action is required.
- If the step is as shown in Image 4, replace the step with a new part of the same part number ensuring that it is engineering change level 01 and has a solid weld in the location shown in Image3.
The change level can be identified by the weld joint at the front of the step. The change level 00 step uses a skip weld and the change level 01 uses a complete weld. Refer to Image2 - Image4 for clarification.
****Affected Product****
Refer to the appropriate service manual as necessary.
1. Inspect the affected product to determine if it is equipped with a remanufactured 3524 engine identified by the serial numbers listed in Image1.
- If the serial number of the installed engine is listed by serial number in Image1, proceed to Step 2. of the Action Required.
- If the installed engine is not listed by serial number in Image1, no further rework action is required.
2. Refer to Image2, Image3, and Image4 to determine if the front engine step was manufactured using a weld as shown in Image3 (Engineering chg level 01) or a skip weld as shown in Image4 (Engineering chg level 00).
- If the step is as shown in Image 3, no further rework action is required.
- If the step is as shown in Image 4, replace the step with a new part of the same part number ensuring that it is engineering change level 01 and has a solid weld in the location shown in Image3.
The change level can be identified by the weld joint at the front of the step. The change level 00 step uses a skip weld and the change level 01 uses a complete weld. Refer to Image2 - Image4 for clarification.
The installed engine serial number must be reported in the warranty claims story to recieve warranty payment.Show/hi