815504232 Mercruiser CLAMP, Worm Gear (2.50 Diameter)

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 "PI3177" 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 "PI3177" 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 with regard to Product Improvement Programs.
Completion Date
January 31, 1999Termination Date
July 31, 1999Problem
GROUP 1
The bolts that attach the existing engine cooling fan adapter to the fan drive pulley can loosen. A new adapter, retained with studs, washers, and nuts needs to be installed.
An incorrect control console fuse/relay panel identification film may have been installed on the panel access door inside the cab. The correct film needs to be installed.
GROUP 2
The bolts that attach the existing engine cooling fan adapter to the fan drive pulley can loosen. A new adapter, retained with studs, washers, and nuts needs to be installed.
Affected Product
Model & Identification Number
GROUP 1
CH65E (6GS224-268, 6GS270-271, 6GS273-275, 6GS278-281, 6GS283, 6GS285-286, 6GS291)
CH75E (6HS235-2466HS248-262, 6HS265-266, 6HS268, 6HS270-281, 6HS283-286, 6HS289-290, 6HS298)
CH85E (6JS246-258, 6JS261-301, 6JS303, 6JS305, 6JS309, 6JS311-312)
CH95E (6KS316-323, 6KS325-328, 6KS330-337, 6KS340-357, 6KS359, 6KS363-369, 6KS371-374, 6KS376-377, 6KS380, 6KS383, 6KS385-386)
GROUP 2
CH65E (6GS1-212, 6GS214-219, 6GS221-223, 6GS269, 6GS272, 6GS276-277, 6GS282, 6GS284, 6GS287-290)
CH75E (6HS1-225, 6HS227-228, 6HS230-234, 6HS247, 6HS263, 6HS267, 6HS269, 6HS282, 6HS287-288, 6HS291-297, 6HS299-300)
CH85E (6JS1-245, 6JS259-260, 6JS302, 6JS304, 6JS306-308, 6JS310, 6JS313)
CH95E (6KS1-315, 6KS324, 6KS329, 6KS338-339, 6KS358, 6KS360-362, 6KS370, 6KS375, 6KS378-379, 6KS381-382, 6KS384, 6KS387-388)
Parts Needed
Dealers will need to order parts for this Program.
GROUP 1
1 - 9F4446 SEAL-O-RING6 - 4M8363 STUD6 - 8T4896 WASHER6 - 6V8801 NUT1 - 1365637 FILM-IDENT1 - 1549731 THREAD LOCK1 - 1611731 ADAPTER-FANGROUP 2
1 - 9F4446 SEAL-O-RING6 - 4M8363 STUD6 - 8T4896 WASHER6 - 6V8801 NUT1 - 1549731 THREAD LOCK1 - 1611731 ADAPTER-FANAction Required
See the attached Rework Procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
GROUP 1
This is a 2.2-hour job.
GROUP 2
This is a 2.0-hour job.
U.S. and Canadian Dealers Only - Eligible dealers may enter a Type 2 SIMS Report.
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)(3-Illustrations)Copy Of Owner Notification For U.s. And Canadian Owners
Rework Procedure
Group 1
1. Remove the engine cooling fan assembly. Refer to "Disassembly and Assembly--3176C Engine Supplement For Challenger 65E And Challenger 75E Agricultural Tractor", Form No: SENR1748, pp.16-17, or "Disassembly and Assembly--3196 Engine Supplement For Challenger 85E And Challenger 95E Agricultural Tractors", Form No: SENR1749, pp. 16-17.2. Remove the (6) 8T-9101 Bolts and (6) 5P-1075 Washers that retain the existing 136-4965 Fan Adapter with installed 9F-4446 Seal. Discard the removed parts. (Refer to Illustration 1.)3. Install the (6) 4M-8363 Studs in the fan pulley threaded holes exposed after removal of the bolts. Apply 154-9731 High Strength Thread Lock compound to the stud (shorter length) threads mating with the pulley as directed. Install full length of stud thread into pulley until seated. Torque the studs to 35 5 N m (26 4 lb ft).4. Install a new 9F-4446 O-Ring Seal into the 161-1731 Fan Adapter.5. Install the 161-1731 Fan Adapter onto the fan pulley/studs. Retain with (6) 8T-4896 Washers and (6) 6V-8801 Nuts. Tighten in a cross pattern sequence. Final tightening torque is 47 9 N m (35 7 lb ft). (Refer to Illustration 2.)6. Reinstall the engine cooling fan assembly. Refer to "Disassembly and Assembly--3176C Engine Supplement For Challenger 65E And Challenger 75E Agricultural Tractor", Form No: SENR1748, pp.16-17, or "Disassembly and Assembly--3196 Engine Supplement For Challenger 85E And Challenger 95E Agricultural Tractors", Form No: SENR1749, pp. 16-17.7. Open and remove the 142-9745 Door As. at the lower front of the right hand control console. (Refer to Illustration 3.) Inspect the Dash Fuse/Relay Identification Film located on the inside surface of the door. The film part number is located at the lower right hand corner. It should read "136-5637 1". If it doesn't, peel the existing film from the door. Clean the surface and install a new self-adhesive 136-5637 Film in the same location.8. Replace the 142-9745 Door As.GROUP 2
1. Remove the engine cooling fan assembly. Refer to "Disassembly and Assembly--3176C Engine Supplement For Challenger 65E And Challenger 75E Agricultural Tractor", Form No: SENR1748, pp.16-17, or "Disassembly and Assembly--3196 Engine Supplement For Challenger 85E And Challenger 95E Agricultural Tractors", Form No: SENR1749, pp. 16-17.2. Remove the (6) 8T-9101 Bolts and (6) 5P-1075 Washers that retain the existing 136-4965 Fan Adapter with installed 9F-4446 Seal. Discard the removed parts. (Refer to Illustration 1.)3. Install the (6) 4M-8363 Studs in the fan pulley threaded holes exposed after removal of the bolts. Apply 154-9731 High Strength Thread Lock compound to the stud (shorter length) threads mating with the pulley as directed. Install full length of stud thread into pulley until seated. Torque the studs to 35 5 N m (26 4 lb ft).4. Install a new 9F-4446 O-Ring Seal into the 161-1731 Fan Adapter. 5. Install the 161-1731 Fan Adapter onto the fan pulley/studs. Retain with (6) 8T-4896 Washers and (6) 6V-8801 Nuts. Tighten in a cross pattern sequence. Final tightening torque is 47 9 N m (35 7 lb ft). (Refer to Illustration 2.)6. Reinstall the engine cooling fan assembly. Refer to "Disassembly and Assembly--3176C Engine Supplement For Challenger 65E And Challenger 75E Agricultural Tractor", Form No: SENR1748, pp.16-17, or "Disassembly and Assembly--3196 Engine Supplement For Challenger 85E And Challenger 95E Agricultural Tractors", Form No: SENR1749, pp. 16-17.Illustrations
Illustration 1. Cross section sketch of existing Challenger E-Series engine fan adapter/fan pulley group