1999 2nd gen bad oil leak

[rkressg]

ow finding quite a few articles and videos about people replacing Cummins stock sheet metal tappet covers with machined billet aluminum ones.
Do you guys think this is a good idea?
It's lookin

Definitely worth the upgrade. At the age/milage on the truck, the old tappet cover is likely bent/warped, and changing the gasket might get you a little time without a leak, but it will eventually start leaking again.
I ended up doing mine twice, because I tried to reuse the sheet metal cover and didn't realize it was slightly bent, and it just kept leaking.
It is a lot of work pulling out the Injection Pump, but I would 99% guess it is the tappet cover gasket. While it is out though, you might as well rebuild the vacuum pump and replace the braided oil hose to the vacuum pump in that area.

 

[RobCN]

We were able to get this done finally. Hope I didn't make a mistake.
My mechanic checked the tappet cover carefully for any damage, bending or warping and found none.
Gasket was badly broken down. Clearly the source of leak.
Replaced the gasket using the original tappet cover.
So far looking good.

Thanks to everyone here for all the help. We were worried that the leak could be from block or head. Whew!!

Rob

 

[GAmes]

I'm not surprised. Many of us have reused the original cover and had zero leaks afterward. I put a stock cover on the current engine, it has over 500k with no leaks. The rebuild sitting on the shop floor has a stock cover too.

 

[BigPapa]

Hope I didn't make a mistake.

No mistake. The billet covers are just bling. I've never seen one bent or warped that wasn't caused by someone.

 

[RobCN]

Tappet cover on my truck is OEM from manufacture circa. 1999. Never been touched until this repair.
Can't really complain.