Explain the KDP details to me...

[sdeeter19555]

Ok, the disassembly, KDP tab fix, crank seal replacement, and reassembly look easy enough for this 90...probably attack that this weekend, figure a few hours and it should be done. Nothing about tearing it apart even concerns me...it's just a matter of getting into it.

My question is in some of the details...

There is talk of removing and loctite-ing the remaining case bolts...where are they? I've watched several videos and nobody actually did anything but the tab?

Further, for the crank seal...the installation tool in particular: is it used to drive the seal home or is it used as a spacer to limit the depth the seal is driven? Is it indexed from the front or from the rear of the cover with the installer?? I actually saw it done both ways...only one (Thorobread Diesel?) said the bore is taper to the rear of the cover and recommended driving to the rear and installing from the rear?

Can anyone give me some guidance?

 

[honobiahunter]

There is talk of removing and loctite-ing the remaining case bolts...where are they? Can’t miss em. You’ll see em when you get the front cover off. A couple are tricky to get to because of the gears

Further, for the crank seal...the installation tool in particular: is it used to drive the seal home or is it used as a spacer to limit the depth the seal is driven? The tool is used for both. However I didn’t have very good luck with it to start it so I used a big socket to start it then used the tool for the depth guide
Is it indexed from the front or from the rear of the cover with the installer?? I first tried it from the front but finally installed it from the backside as someone else had suggested...much easier. You can also put the seal in the freezer for a couple hours to help shrink it some to make for an easier installation. I also used locktite on the outer edge of the seal prior to driving it in. Not sure if it’s needed but I’d saw it recommended

Good luck

 

[sdeeter19555]

Thanks, because I started another part, this will be something I tackle the first part of September.

 

[Dick Langendorff]

Steve, I really admire your devotion to the details. No reason to repeat steps one and two if they will not give you the results.
I hope you got your brakes taken care of. When I sold my ‘89 I let the new owner have the service manual. I would have sent it two you. I have my 2004 manual.
The Cummin’s website might help you with some of the engine questions.
Keep up the great work and “high determination”.

 

[Timd32]

Have you downloaded the "ALL Years Buyers Guide"

Page 242 starts the article, could be in a different issue, but has a bunch of pics and the sort.

https://www.turbodieselregister.com/threads/tdr-buyers-guide-all-years.263521/

 

[Philip]

Most of us just drove the pin in to the bottom and peened the case hole with a sharp punch. That will stop the pin from moving.

The case bolts if you check will be loose. The camshaft retainer bolts will be loose to. The camshaft retainer bolts are the biggest issue. A pin coming out just cracks the timing case 90% of the time. If a cam retainer bolt comes out. It will get very expensive fast. It will break the camshaft. It will take out the timing case and cover and maybe the injection pump drive gear. It will also bend every valve in the engine.

Do all the case bolts and camshaft retainer bolts with Loctite.

 

[sdeeter19555]

The camshaft retainer bolts, there are just two? I assume they can be accessed without pulling the gear?

 

[sdeeter19555]

Ok, tore it down tonight...

Damper was the worst part, it was rusted to the stub on the crank. A little tapping and a little prying got it loose.

I found my fan shroud is busted...anyone have a spare?

For the fan, I had to grind a 10mm down thin enough to get at that one bolt. I had a cheapy wrench just for that reason. Bearing seems good, no reason to change it out.

I tabbed the KDP...it was flush with the end of the case bore, I drove it back about 3/8". Tabbed it tonight, I need to the others but it was enough for one day.

I pulled the AC compressor, that was a pain. Does the main cast iron bracket really house the inlet neck as well? It looks like that entire thing is all one piece? It should make changing the filter easier.

Now I have some questions:

Some of the bolts are behind the gears...and there is no lining them up with a gear window. How do you get to them? I can see the one bolt is behind the web of the gear, so no getting to it.

Another question about the cam bolts, what are they torqued to? I could probably look it in the FSM, but I'm not sure it gets that deep.

My cover gasket came off in one piece...would you reuse it? I've read both ways...I could use it or used gray RTV.

 

[Joseph Donnelly]

You can reuse the gasket after cleaning it. Put gray or black RTV on it. Bolts take 18 ft lb. There are 3 case bolts behind the cam gear. You can get straight onto two by turning over the engine until the cam gear window lines up. The third is offset so I use an open end 10 mm wrench that I have bent about a 30 degree angle just past the part where the bolt head goes.

 

[sdeeter19555]

You can reuse the gasket after cleaning it. Put gray or black RTV on it. Bolts take 18 ft lb. There are 3 case bolts behind the cam gear. You can get straight onto two by turning over the engine until the cam gear window lines up. The third is offset so I use an open end 10 mm wrench that I have bent about a 30 degree angle just past the part where the bolt head goes.

Well that's disappointing...according to the TST instructions there were only two bolts under the timing gear?

I ended up completing it tonight...four case bolts under the cover (including the KDP), two at the oil pan flange, and the two cam retainer bolts.

 

[sdeeter19555]

This is the TST instructions from the Geno's Garage KDP kit...

 

[Timd32]

"2" are under the physical gear where those arrows are pointing, there are additional as you found holding the cover to the block. I skipped those 2 on mine. Or one of them that was not able to get too. Nothing was loose on mine.

IMO, If they have not worked their way loose by now your fine. It's been many miles and years, heat cycles and the sort.

Have not heard recently of any KDP failures, not saying there not out there but my guess is this is a very old problem the bulk have already fallen out that were going to fall out.

Even being out the little bit yours was out who knows how far in it was ever to start with.

Better safe then sorry for sure, plus the front seal service is good to get done. I did mine mostly due to a leaking front seal.

Sounds like you made out ok. Good job.

 

[sdeeter19555]

I've read two instances just recently where there were KDP failures (both 1st gen trucks), being I had no service history on this one; I wasn't taking any chances.

I did find one bolt semi-loose, the lower left one (above the crank) under the cover. The rest snapped loose...no thread locker.

So which is it, two or three under the cam gear; I did two? Curious minds want know....

 

[Fastback67]