806871 Mercruiser GASKET

March 6, 2001
(Revised February 2002)
U-51
A-35
AU-29
O-37
Beforeor
after failure PRODUCT SUPPORT PROGRAMFOR REPLACING THE ENGINE COOLANT RECOVERY BOTTLE ON CERTAIN CH65E, CH75E,CH85E, AND CH95E CHALLENGERS
1354 PS40485
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS40485"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe March 6, 2001 Service Letter. Changes have been made to the TerminationDate.TERMINATION DATE
March 31, 2003PROBLEM
The engine coolant recovery bottle on certainearly production Challenger E-Series tractors may develop cracks due tocontinued exposure to ultraviolet sunrays. An improved bottle with enhancedultraviolet resistance is now available. Early production tractors maybe reworked with the new bottle assembly.It is suggested that the customer be providedthe Parts Needed and Rework Procedure (under terms set forth in the ServiceClaim Allowances) for his installation. The dealer may also choose to makethe installation in conjunction with another service call. In either case,no labor is provided by this program.AFFECTED PRODUCT
Model Identification NumberCH65E 6GS1-593CH75E 6HS1-201, 203-276, 278, 280-595CH85E 6JS1-296, 298-615CH95E 6KS1-857PARTS NEEDED
1 - 1630423 Bottle (Tank) As.ACTION REQUIRED
***** Parts Stock *****Remove all 1401207 Tank As. from parts stock.***** Affected Product *****See the attached Rework Procedure.SERVICE CLAIM ALLOWANCES
***** Affected Product *****
Product smu/age whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-5000
0-60 months 100 % 0 0 0 0 1
This is a 1.0 - hour job.***** Parts Stock *****Submit one claim for all 1401207 Tank As. removedfrom parts stock.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Reference Illustration 1 whencompleting the following rework steps.
1) Locate the engine coolant recoverybottle on the left side of the tractor below the cab.2) Loosen the nuts at either end ofthe two recovery bottle retaining strap assemblies.3) Loosen the clamp retaining the overflowhose to the fitting at the top of the bottle. Remove the hose.4) Remove the front fender mountingbolts and hard washers, which also secure the coolant recovery bottle supportbracket. Retain the removed fasteners.5) Pull the support bracket and bottleoutward to clear the frame rail. Loosen the clamp retaining the hose connectingthe recovery bottle to the radiator. Remove the hose and drain the enginecoolant into a suitable container for recycling or disposal.6) Remove the nuts, hard washers, andretaining strap assemblies securing the recovery bottle to the supportbracket. Retain.7) Remove the bottle from the bracket.8) Install the new 1630423 Bottle (Tank)As. in the support bracket. Secure with the retaining strap assemblies,hard washers, and nuts removed in Step 6.9) Reattach the support bracket (withrecovery bottle) using the fender mounting bolts and hard washers removedin Step 4.10) Reattach the overflow hose to thetop bottle fitting, and tighten the retaining hose clamp.11) Reattach the radiator-to-bottlehose to the bottom bottle fitting, and tighten the retaining hose.12) Refill the overflow bottle to thecorrect level. Bring the engine to normal operating temperature and recheck.
Item No. Part No. Description