Caterpillar 3406 Overhaul Kits by Arrangement Number

Every Caterpillar 3406 engine is built with a specific arrangement number, which acts as a blueprint for the engine’s design. The arrangement number determines the piston style, liner dimensions, connecting rods, bearings, and other critical specifications. When it comes time to overhaul a Caterpillar 3406, choosing the correct rebuild kit requires careful alignment with your engine’s arrangement number.

By matching an overhaul kit to the correct arrangement number and serial number prefix, operators ensure that every component—pistons, liners, bearings, gaskets, and seals—fits properly and restores the engine to its original performance. Using the wrong kit can lead to mismatched compression ratios, poor sealing, or premature wear, which is why Diesel Pro Power organizes rebuild kits by exact engine configurations.

Below, we break down the Caterpillar 3406 overhaul kits available for supported arrangement numbers and serial prefixes.

Rebuild Kit for Caterpillar 3406 – 14.5:1 Compression Ratio

One of the most common Caterpillar 3406 rebuild options is the in-frame kit designed for engines operating at a 14.5:1 compression ratio. This ratio plays a vital role in combustion efficiency, fuel economy, and power output.

A diesel engine compresses air to extremely high pressures before fuel injection. The compression ratio is the measurement of how much the air is compressed compared to its original volume. At 14.5:1, the Caterpillar 3406 achieves an ideal balance of fuel economy and power density, making it one of the most efficient workhorses in Caterpillar’s lineup.

When engines with this specification begin to show reduced compression, excessive oil consumption, or loss of power, an overhaul kit with the proper piston and liner design is required. This kit restores combustion chamber geometry, ensuring that the engine once again delivers the performance levels intended by Caterpillar.

Applications for the 14.5:1 Overhaul Kit

Engines with a 14.5:1 compression ratio are often found in heavy-duty industrial equipment, marine propulsion, and power generation units. These engines are designed for sustained load and long operating hours, which means piston rings, liners, and bearings naturally wear over time. An in-frame overhaul kit allows operators to rebuild the engine without fully removing it from its installation, saving both time and labor.

Supported Arrangement Numbers

The following arrangement numbers are supported under the 14.5:1 compression ratio rebuild kit:

2W1900, 7N2617, 8N9999, 1109524, 1109525, 1109698, 1778865, 1778866, 1778869, 1778870, 2W7067, 4W3800, 4W3801, 7W7264, 1315403, 1315404, 1315406, 1778873, 1778874, 1778875, 1778876, 1778877, 1778878, 1778879, 1778880, 1093830, 1093839, 1206694, 1206695, 1206700, 449630, 2385342, 2385343, 2385344, 2385345, 2385348, 2385349.

Listing the arrangement numbers ensures that operators can match their exact engine build to the correct overhaul kit. Each arrangement number represents a unique configuration of the Caterpillar 3406, and the rebuild kit accounts for these differences in piston crown design, liner thickness, and gasket specifications.

Supported Serial Number Prefixes

Engines with the following serial number prefixes are covered by this kit:

91U, 4BT, 2AM, 1SS, 4BM, 4T7, PFH.

These prefixes help identify the production batch and build family of the Caterpillar 3406. Cross-referencing both the arrangement number and the serial prefix guarantees the correct parts selection.

Rebuild Kit for Caterpillar 3406 – Arrangement #4N2239

Certain Caterpillar 3406 engines were produced under arrangement number 4N2239, which carries its own specifications. Engines with this arrangement number require a dedicated overhaul kit to ensure that the pistons, liners, and bearings align precisely with the factory design.

This rebuild kit includes all major in-frame components, such as:

• Pistons and liners matched to Caterpillar specifications

• Piston rings for proper sealing and compression restoration

• Connecting rod bearings and main bearings for reduced friction and load support

• Cylinder head gasket and lower gasket sets to ensure complete resealing of the combustion chamber

By using the correct kit for arrangement 4N2239, operators can restore the engine’s reliability and performance without the risk of component mismatch.

Supported Arrangement Numbers

4N2239.

This arrangement number identifies a specific build of the Caterpillar 3406 that differs in piston design and other small tolerances compared to the 14.5:1 compression engines listed above.

Supported Serial Number Prefixes

91U.

The 91U prefix is one of the most common identifiers for Caterpillar 3406 engines and confirms compatibility with this particular rebuild kit.

Alternative Rebuild Kit for Caterpillar 3406 – Arrangement #4N2239

In addition to the standard rebuild kit for arrangement 4N2239, an alternative version is available. This option is designed for operators who require a slightly different component configuration but still need full compatibility with their Caterpillar 3406 engine.

Just like the primary kit, the alternative option restores critical compression and performance, ensuring long-term engine reliability. The difference lies in certain gasket materials and piston crown specifications, allowing technicians to select the best fit for their application.

Supported Arrangement Numbers

4N2239.

This confirms that both the standard and alternative rebuild kits are designed exclusively for engines built under the 4N2239 arrangement.

Supported Serial Number Prefixes

91U.

As with the standard kit, engines carrying the 91U serial number prefix are fully compatible with this alternative option.

Why Arrangement Numbers Matter

Caterpillar engines are built for a wide range of uses, from marine propulsion to stationary power generation. Even within the same 3406 family, small variations in piston design, gasket thickness, and liner diameter can exist. These differences are tracked by the arrangement number, which acts as the “fingerprint” of the engine.

When overhauling a 3406, operators cannot rely solely on the model name. Two engines both labeled as “3406” may require completely different pistons or compression ratios. Selecting a rebuild kit without confirming the arrangement number risks costly downtime, misfit components, or even catastrophic engine failure.

This is why Diesel Pro Power catalogs overhaul kits by arrangement number and serial prefix—giving customers absolute confidence that the kit they order will match their specific engine.

Restoring Caterpillar 3406 Performance

An overhaul kit matched to the correct arrangement number is more than just a box of parts—it’s a complete solution for restoring engine performance. By replacing the pistons, liners, bearings, and gaskets with new, properly fitted components, operators can expect:

• Restored compression for reliable combustion and power output

• Reduced oil consumption thanks to new piston rings and liners

• Improved fuel economy from a properly sealed and balanced combustion chamber

• Extended engine life through new bearings and precision gaskets

With the Caterpillar 3406 being a cornerstone of many fleets and industrial applications, keeping it in peak condition with the right rebuild kit ensures continued uptime and dependable operation.

Gasket Sets for Caterpillar 3406 Engines

When performing a rebuild or even a partial in-frame repair on a Caterpillar 3406, the quality of the gaskets and seals you install is just as important as the pistons and liners themselves. A gasket failure can undo the hard work of an overhaul, leading to coolant leaks, oil leaks, loss of compression, and even catastrophic damage. That’s why Diesel Pro Power provides Caterpillar 3406 gasket sets tailored for specific repair scenarios.

In-Frame Gasket Set

The in-frame gasket set is designed for situations where the engine remains installed in the chassis or engine room. Often, operators notice oil seepage, coolant contamination, or reduced compression that requires attention, but a complete teardown may not be practical. In these cases, an in-frame repair—replacing liners, pistons, and related gaskets—restores reliability without removing the engine block from its installation.

An in-frame gasket set for the Caterpillar 3406 typically includes:

• Cylinder head gaskets for proper combustion sealing

• Valve cover gaskets to stop oil seepage at the top end

• Intake and exhaust manifold gaskets for consistent airflow sealing

• Liner seals and O-rings to prevent coolant and oil cross-contamination

• Miscellaneous small gaskets and seals needed during disassembly and reassembly

Because the Caterpillar 3406 is often found in marine vessels and heavy equipment where downtime is costly, an in-frame gasket set allows crews to perform targeted repairs quickly while extending the working life of the engine.

Complete Overhaul Gasket Set

For engines that require a full teardown and rebuild, the complete overhaul gasket set is the ideal solution. This set includes every seal and gasket necessary for a complete disassembly and reassembly of the Caterpillar 3406.

A full gasket set ensures that once the engine is rebuilt, all surfaces are resealed to factory specifications. Operators gain confidence that no weak points are left unaddressed, which is especially critical in marine and industrial settings where 3406 engines run continuously under heavy loads.

Key advantages of using a complete overhaul gasket set:

• Comprehensive coverage: Every gasket is included, reducing the risk of missing a critical seal.

• OEM-quality materials: Gaskets are engineered to withstand extreme temperatures and pressures.

• Time efficiency: Technicians can complete the rebuild without having to order additional sealing components mid-project.

Whether you are overhauling a Caterpillar 3406 on a vessel at sea or rebuilding one in a power plant, having a complete gasket set on hand ensures a smooth process from start to finish.

Supporting Tools for Caterpillar 3406 Overhauls

Rebuilding a Caterpillar 3406 requires more than just parts—it also demands the right tools. Without proper tooling, technicians risk damaging critical components during disassembly and reassembly. Diesel Pro Power supplies professional-grade tools that make maintenance faster, safer, and more efficient.

Fuel Filter Removal Wrench

The Caterpillar 3406 relies on a clean, well-maintained fuel system for proper performance. When replacing filters during routine service or during an overhaul, having the right wrench prevents damage to filter housings and ensures a tight seal on new components.

Our fuel filter removal wrench is adjustable to fit filters ranging from 3-7/16 inches to 3-3/4 inches, making it suitable not only for Caterpillar 3406 engines but also for related diesel platforms. By using this tool, operators avoid the common mistake of overtightening or stripping filters during installation.

Oil Filter Removal Wrench

Oil is the lifeblood of any diesel engine, and the Caterpillar 3406 is no exception. During an overhaul, oil filters must be removed and replaced to ensure clean lubrication for new pistons, bearings, and liners.

The oil filter removal wrench accommodates filters ranging from 4-21/32 inches to 5-5/32 inches. This wide adjustability ensures it works on Caterpillar 3406 filters as well as other heavy-duty engines. With this tool, technicians can quickly remove stubborn filters without risk of cracking housings or damaging the filter mount.

Selecting the Correct Caterpillar 3406 Overhaul Kit

Choosing the right overhaul kit for your Caterpillar 3406 is a precise process. Ordering based only on the “3406” name is not enough. Many operators make the mistake of assuming that all 3406 engines share identical components—but in reality, arrangement numbers and serial number prefixes dictate critical differences in pistons, liners, and gaskets.

Here are the key steps to ensure you select the correct kit:

1. Locate the Engine Data Plate
   Every Caterpillar 3406 has a data plate affixed to the engine block. This plate lists the arrangement number and serial number prefix. These identifiers should always be used when ordering parts.

2. Confirm the Compression Ratio
   Engines built under different arrangements may run at different compression ratios. For example, the 14.5:1 compression rebuild kit includes pistons designed specifically for that ratio. Installing the wrong pistons will alter combustion efficiency and reduce performance.

3. Understand Your Application
   A Caterpillar 3406 powering a marine vessel has different operating stresses compared to one running a generator set. Ensuring the correct gasket materials and piston design for your application will maximize longevity.

4. Consult Diesel Pro Power Experts
   With more than 40,000 customers worldwide, Diesel Pro Power has the expertise to guide operators in selecting the right kit. Our team helps match your arrangement number and serial prefix to the exact overhaul components required.

Why Diesel Pro Power for Caterpillar 3406 Overhaul Kits?

With decades of experience in the diesel engine industry, Diesel Pro Power has become a leader in supplying Caterpillar 3406 overhaul kits worldwide. Here’s why operators trust us:

• Exact-Fit Kits: Each kit is tailored to specific arrangement numbers and serial prefixes for perfect compatibility.

• Worldwide Shipping: Parts are stocked and shipped quickly, minimizing downtime for marine vessels and industrial operations.

• Trusted Reputation: With 40,000+ satisfied customers, Diesel Pro Power is recognized globally for quality and reliability.

• Professional Support: Our technical team assists customers in selecting the right kit, ensuring hassle-free installations.

By choosing Diesel Pro Power, operators gain confidence knowing they are investing in OEM-quality Caterpillar 3406 rebuild kits that restore performance and reliability.

Restoring Your Caterpillar 3406

The Caterpillar 3406 has earned its reputation as a durable and dependable workhorse in both marine and industrial settings. But even the best engines eventually require major service. With a correctly matched overhaul kit, operators can:

• Extend the working life of their 3406 by thousands of hours

• Restore factory-level fuel efficiency and compression

• Reduce oil consumption and emissions

• Prevent unplanned downtime and costly failures

Whether you are maintaining a vessel’s main engine, a backup generator, or heavy equipment, Diesel Pro Power’s Caterpillar 3406 overhaul kits provide everything you need to get back to work with confidence.