Engine/Transmission (1994 - 1998) Dodged KDP bullet.

[CRWilliams]

Well, a couple of months ago I decided it was time to change the leaking front main seal, bump the timing, and tab the KDP while I was there. Imagine my shock when I pulled the front cover off and heard a small metallic clunk on the floor. :--)



You guessed it, the KDP had fallen out. My stars were with me though and the pin bounced on the gear, turned sideways and rode on the gear for who knows how long. There was a dent in the front cover, but there doesn't seem to be any other damage. Here are some pics.



My question is this. Do I need to replace the pin or can I just run it without the pin? I know the pin is used to align the gear housing, but is it needed after the gear case is bolted down. I checked all the bolts and a couple were loose, so I tightened them. I have been running it without the pin for a couple of months, but I am starting to worry. How about some expert opinions from you guys.

 

[Coalsmoke]

Wow you are so lucky. As long as all your bolts are tight I wouldn't worry about it, but I'm not an expert just an enthusiast.

 

[WDimig]

you'll probably be ok, but if it were my truck i would have put a new one in, that pin keeps the gear housing lined up at the top, there is another pin that is twoards the bottom of the case by the oil pump, but without that pin at the top, if the bolts were to loosen up again, the case might shift, possibly causing a oil leak, soo if you got the time, i would go back in, put in a new pin, and put a tab over the pin, and forget about it. just my $. 02 cents



wes

 

[Joe G.]

The heavy P7100 pump is hanging on the gear case. You need the pin to keep it exactly in place.

 

[WilsonF]

In all the posts I have read, and what I did was, put pin in. It might not be alined. Pull bolts out, one at a time put loc-tite and re install. Go to TST web site. There are a few hidden bolts the site will tell you how to find them. Yes put one back in.

 

[bigdaddydieseldan]

boy you sure are one lucky sob good for you glad you didn't end up with any damage :-laf :-laf



I would definitely go back in and replace the pin also I would remove all 5 bolts clean them up clean out the holes and loctite the bolts and torque theem down to factory specs

 

[Dave M]

As others have said... I would definately put in a pin (Cummins probably has them) with a TST tab and also remove all the (11 bolts I think) case bolts and clean the bolts and holes with brake cleaner and put blue locktite on each one. The torque is around 12 ft-lbs or something like that. . its not much.



Any one of them bolts could come out and fall in there and cause more damage then the pin cause they are probably harder. Someone on here had pics of the carnage done by one of them 11 or so loose housing bolts... . and it was not pretty.



Just curious... how many miles on your engine?

 

[CRWilliams]

Well, thanks for the input guys. I guess I'll go hit Cummins and get a new pin. Yeah, I feel very fortunate not to have the case broken. Dave, the engine had 160,000 on it or so when I found the pin. It had obviously been out for some time though, as evidenced by the fact that almost half of the pin has worn away. I bought the truck with about 135,000 miles on it from a teenager and know the truck got beaten pretty hard. I met someone who knew him and said that he always drove it like he stole it. He said all 4 tires have been 5 feet in the air. Really says something about the durability of the Cummins. I was going to post another thread about a broken pushrod I found in the engine after I let a friend borrow it. Never heard or seen that before either.

 

[Dave M]

I did my pin a couple years ago and it was 1/8 in out. I have 223K mi now so it had about 185K on it when KDP was tabbed.



These trucks can sure take a beatin. The worst thing I have to complain about is putting $2K+ into the poorly design front end and steering but now it rides smooth. Dragging around 7100+ lbs on these dirt roards up here probably puts a lot of stress on this truck so I guess I can't complain. I still love this truck... er... Cummins anyhow.

 

[OPoole]

I have only seen 2 trucks be this lucky your's is the 3rd.

 

[Coalsmoke]

The heavy P7100 pump is hanging on the gear case. You need the pin to keep it exactly in place.

Joe is right, when you consider the P7100, the vac and steering pump all on that side, I guess it would be smart to put the pin in. I read somewhere once that the 2 pins were there for correct factory assembly process.

 

[Breed]

Wow! great luck, Dude! I'm sure glad it didn't cause any damage, I did my KDP a while ago and it was out 1/8 a inch and that made me a big believer. Good job!

 

[95REDRAM]

I think you should go buy a lottery ticket.