0200737 JOHNSON 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 must be administered as soon as possible. When reporting the repair, use "PI3980" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3980" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Refer to your Warranty Bulletin for detailed information in regards to Product Improvement Programs.
Completion Date
July 31, 1997Termination Date
January 31, 1998Problem
The 7W1632 Crankshaft Oil Plug may become loose and cause a loss of oil pressure to the connecting rod journal.
Affected Product
Model & Identification Number
3606 (8RB290-298, 8RB301-305, 8RB307-352, 8RB354-365, 8RB367-386, 8RB388-436 , 8RB438-446, 8RB448-620)
3608 (5PG1-15, 5PG101-105 6MC240-244 , 6MC246-342, 6MC344-519, 6MC521 8LL3-6 7WR1-10 )
3612 (9FR13-16 9RC13 , 9RC15-22, 9RC24, 9RC25, 9RC27, 9RC28, 9RC30, 9RC32, 9RC36-50, 9RC52-60, 9RC62 , 9RC64-73, 9RC75, 9RC77-85, 9RC87, 9RC88, 9RC90, 9RC92, 9RC93, 9RC95, 9RC99 , 9RC102-106, 9RC108-112, 9RC115-122, 9RC125-152, 9RC155, 9RC157, 9RC159 , 9RC160, 9RC164, 9RC165, 9RC167, 9RC168, 9RC171-190, 9RC192-226)
3616 (1PD18, 1PD19, 1PD22-54, 1PD59-90, 1PD92-134, 1PD136-143, 1PD148-158, 1PD160-196 , 1PD198-207, 1PD210, 1PD212-231, 1PD233, 1PD234, 1PD236-247 1PD249 , 1PD251-264)
Parts Needed
Dealers will not need to order parts for this Program.
Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
3606 and 3612 Engines claim 6 hours labor. 3608 and 3616 Engines claim 8 hours labor.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
This program requires that all crankshaft oil plugs be checked for proper torque. If a plug is found not to be at the specified torque it will need to be removed, properly cleaned, and reinstalled as outlined below. The following inspection will need to be performed during the next scheduled oil change or overhaul, whichever comes first.
1. Remove the crankcase side covers on one side of the engine and rotate the crankshaft so that the 7Wl632 Crankshaft Plug is accessible for the plug you are checking.2. Use a torque wrench set to 300 40 N m (220 30 lb ft) to verify torque. Mark the 7W1632 Oil Plug for location to check for movement while applying torque in the tightening direction. If the plug rotates prior to the torque wrench click, proceed to step three. If the plug does not rotate proceed to the next plug.3. Remove the plug and allow the oil to drain from the threaded area in the crankshaft. Clean the threaded area of the crankshaft with Loctite 7070 Cleaner. Remove all excess cleaner from the threaded area before reinstalling the oil plug.4. Clean the threads on the oil plug thoroughly and apply Quick Cure Primer (4C9500, 6 fl oz. Aerosol, or 6V1541, 6 fl oz. pump type) to the threaded surface of the plug. Let the plug dry completely and then apply Loctite 609 (4C4032, 10 fl oz., or 7M2453, 3 fl oz.) on the threaded surface of the plug. Install the plug and tighten to a torque of 300 40 N m (220 30 lb ft). Do not install plugs that have the pre-applied Loctite 203 (silver) on the threaded area. If a plug must be replaced make sure that the threads are thoroughly cleaned, and installed using Loctite 609.
5. Proceed to the next plug until all plugs have been checked.