Engine/Transmission (1998.5 - 2002) Improved front gear cover

[Paul Somers]

OK. I have the front cover off my 1999 24 valve engine to inspect the KDP possibility. I think I have the new improved cover. Would take picture but difficult with radiator on. Any way my cover would not work with the TST fix because there is a raised portion around the dowel pin that is a higher plane than the bolt. Before I put this thing back together I want to make sure there is nothing I need to do about this dowel pin. I want it right so I can quit worrying about my engine tearing up because of a $. 75 dowel pin.

 

[Ncostello]

Paul... your cover has whats known as the bossed pin bore. Some covers didn't and the tab would work. Later they added the bossed area but the bore was still open. Finally the improved cover was bossed and the pin bore opening had a very... very... minor lip edge around it at the end. If the pin wiggled out it could come all the way to the surface and be stopped. Its also known as a stepped hole.



There are some things you should do. First is take a short flat faced punch and a heavy hammer. Strike the pin with the punch/hammer and make sure its seated. Mine only moved 0. 005" as measured with a depth micrometer.



Next you need to determine if you have the stepped hole. Take something like a stiff wire and put a 90 degree bend on the tip... kinda making a hook end. Only bend about 1/8" so it can slide in the pin bore. Now drag the wire along the bore. When you reach the end (as in your coming out into the gears) it should snag on the lip edge. Drag it on the sides and top of the bore. It should be halted in all four places. Its hard to see the step in the bore. I have a scratch awl with a bent tip. Its very sharp and catches the lip very well. Make sure you sharpen the wire tip... otherwise a rounded off end may not catch the lip and you might end up thinking your dont have it when you do.



For further precaution, take a sharp punch, stick it into the bore and strike it solidly with a hammer to make a stake hole... or a dent in the aluminum bore. That deformed area will also keep a pin from sliding out since it rides snug in the bore.



Finally purchase green wicking loctite and squirt some in the hole... mop up the excess with a q-tip. Let it dry for a while if possible.



It wont come out now even if you dont have the stepped hole. You are now free to drive the crap out of it without worry.

 

[John]

If I'm not mistaken, you are referring to the raised boss on the aluminum gear case itself (located beneath the steel gear case cover), not the gear case cover as stated in both of the preceding posts.

 

[Paul Somers]

Thanks

Thanks to all that replied especially Ncostello. It seems that I have the raised boss pin bore but no step. I tapped with punch and ball peen hammer and it seemed as though it was bottomed out. I could use mirrow and light and stiff wire with hook to see there is no step in the bore. I will do as suggested and with a center punch stake the bore and use green loctite. Only way the tab would work is if it was 'Z' shaped. Using the jig fix on a cover like this would have to deposit filings into your oil pan. IMHO removing the cover is the only proper way to check for this problem.

 

[Ncostello]

I too asked the question a few times about jigging a bossed style cover. That drill bit would really be putting some shavings in there as it goes through the bossed area. I'm not for sure... but it appeared to me, from photos, the machine screw goes flush against the hole of a regular case. If thats true, the drill bit would certainly be drilling alot of material in there.



Mine felt bottomed out too. I had the improved cover but aplied loc-tite and staked it anyway to keep if from moving at all.



Wonder why in the world they didn't just make it a blind hole. After all you have to install the pin before the case anyway. There is really no purpose I can think of for the hole to be open at all. Oh well... good luck.