Engine/Transmission (1994 - 1998) bolt falls out in front gear case breaks camshaft

[MUDDY]

well,,,,,,,,,,,,,,,i guess when doin a kdp it best to pull front cover and locktite and tighten all the bolts. lots of kdp's have fallen out and caused damage but have never seen evidence of, or talked with anyone who has seen a bolt drop out before. have heard of folks finding slightly loose ones tho. well,,,,,,,,,,,,got to see a rig at harolds that has suffered this cruel and uncommon malady. bummer... ... ... ... ... ... ... ... ... ... .



our new poloicy here is to still continue to use jig method to retain kdp as setscrew is cheaper than a tab. but,,,,,,,,,,,,,,,,we will remove front covr and tend to the bolts properly. a rare occurance but it can happen and in the opinion of several now it is worth it to take care of it b4 it has a chance to play hell



pics of the carnage will follow later



link to a few comments on subj by harold

https://www.turbodieselregister.com/forums/showthread.php?s=&threadid=98983&perpage=15&pagenumber=1

CB, I would bet you have a cracked or broken case.

the pin can't get thru without breaking it. (IMO)

if I were you I would take off the cover and if the case

isn't broke I would reinstall the dowell pin and stake it

good. the case is thick enough to do that. the pin will be

recessed about 1/4 inch. then I would take out the 4 bolts

that you can get out,clean them and the holes and loctite

them. the 5th bolt you can loosen some and put some green

wicking loctite onit too. I learned just recently that one of the

bolts is more apt or just as apt to fall out as the KDP.

I have a 92 in my shop right now that done just that. the

lower bolt(inside case) on passenger side fell out and broke

the camshaft, bent half the push rods, and some lifters, and

I don't know what else yet. it done major damage. I would

rather have a dowell pin fall out . I was able to fish the bolt

out w/magnet. (the dowell pin was still in and seated)

this truck has 234k miles. hbowers





__________________

04 3500 laramie drw 48re HO 3:73

stock so far. Reece 16K 5th wheel

hitch. pull a 31 alfa ideal.

di-pricol gauges(pillar mount) cool

down timer. DD and edge goodies

soon.



------------------------------------------------------------------------------

When the pushrods bend, thge valves are tweaked and you need to do a valve job and be sure none are bent noticeably.





__________________

Joe

1997 club cab 4x4 5 speed; 799. 9 hp on #2 fuel with Bell turbo, DonM, & a number of Diesel Dynamics toys.

2004 SLT QC 4x4 HO 6 speed; DD goodies.

--------------------------------------------------------------------------------

 

[QRTRHRS]

That's what happened to my neighbor's second gen. He came over to see mine when I was tabbing it and pointed out the bolt but I don't remember which one it was. Snapped the end with the gear off the cam. He ended up replacing the head. Now that spring's here, we see each other out working the fields. I will ask him about it again next time.

 

[Joe G.]

Why mess with a jig if you have to take the cover off anyway? I don't know how the set screw can be any cheaper than my tab. I made it out of a piece of scrap steel I had.

 

[hbowers]

Joe G. how thick did you make your tab? did you use the

same bolt or a longer one? just wondering. hbowers

 

[Forrest Nearing]

a tab is like $2 and if you're already going to have the cover off, it seems like less work than the jig method

 

[Joe G.]

I think my tab is about 3/16" or so. I just rooted around in my scrap until I found a little piece of steel. I didn't really pay much attention to how thick it is. I used a longer bolt because the original is just barely long enuff to hold he gear case on without the tab. TST is selling a kit that has everthing except the big gasket so that is what I reccomend when someone asked me for the instructions on how to do the job.



The tab only takes a few minutes to make so buying the kit from TST is not neccessary. It's just convenient.

 

[Forrest Nearing]

Cummins sells the tab also... I think it lists for like $1. 98



Forrest

 

[Camara]

I just had the same thing happen to my 93. Bolt fell out and broke a pile of stuff. Cam, crank gear, lifters and bent all the pushrods.

 

[Deezul1]

The 2 I have done both had bolts that had maybe 10lbs of torque on them, they tightened quite a bit.

 

[MUDDY]

here is some carnage pics from the 92 harold did

:{



#ad






#ad






and the bolt that fell out and caused all this carnage

#ad

 

[Camara]

That is the exact same bolt that fell out on me. Pics look exactly like the damage I had. All my push rods bent and the tops of all the lifters broke off. I had to take the pan down and get the rest of the pieces.