Engine/Transmission (1994 - 1998) Jig for KDP

[edgeman]

Can anyone help me find a jig tool for the KDP and is the nut for the fan opposite threads.

 

[surfbeetle]

When I did my KDP, I used the $50. 00 kit from TST Products, no jig required. Also, it is not necessary to remove the fan itself, the entire fan assembly, including the bracket, will come off the front of the engine and allow you access to the front cover.

 

[wcjp]

I'm not sure who holds the jig in your area. Now is a good time to inspect the radiator. If it's real dirty now is the time to pull it for cleaning.

 

[Joseph Donnelly]

As another person noted, the TST kit uses a tab method and is satisfactory and priced reasonably vs. rental of a jig. More importantly, the TST method involves removal of the cover whereas the jig method just drills through the case from outside it. Removal of the gear case cover allows you to check the tightness of the bolts inside it, and preferably remove, clean, and loctite them into place. The five bolts holding the gar case to the block are most susceptible to loosening. If one falls out, its flange head can catch between gear teeth and result in even greater damage than the killer dowel pin causes (the dowel is too big in diameter to fall between the teeth and lock up the engine). You can get directly on two of the bolts, two more are accessible through “windows” in the cam gear if the engine is cranked over so one of the three windows exposes the bolt, and the fifth can be reached (but not removed) to tighten it with a bent open end wrench through one of the windows (it is farther outboard, toward the gear teeth). The two cam retainer bolts and four oil pump bolts do not usually loosen but should be checked. Yes, the fan hub has left hand threads in the first and second generation trucks.

 

[edgeman]

Thank to all who replied. We have the fan out, the radiator, the inercooler and condesor, and the cover over the front gear case out. We found that the dowel pin is not in the case it is no were to be found. The gear case has a major and im talking 1. 5"x1. 5" chunk that fell out and was JB welded back in. I did not do the JB welding it was done before i bought the truck. After i bought the truck it decided to start leaking really bad. so now My dad and i are fixing it and we would really like it if someone would send us the info on the whole project. Getting the stuff out that we have out was the easy part. now comes the time to get the camshaft gear and the shaft out from what i have herd form Joseph Donnelly and others that is the hardest part, so if someone has any suggestions or info that would be greatly appreciated. Im 16 and Me and My dad are used to working on small toyota motors so stepping up to this is a bit of a change. Thanks Ethan

 

[Joe G.]

Look here: CumminsDatabase.com :: 12V Dowel Pin Repair

 

[fest3er]

Well, the advantage to the Cummins is that it's so big (in comparison), you have lots of room to work. Or, it's easier to rebuild a sundial than it is to rebuilt a Swiss watch.

So long as you aren't in a hurry to get it back on the road, don't rush. Take your time and do it one step at a time. If a particular task seems daunting, work it through in your head until you have a good idea how the things are supposed to come apart and go together. Hard jobs are much easier when you have 'the picture'. If something doesn't seem right, stop and picture it. And if you have to reverse some steps, reverse them.

An engine is an engine, be it a 'yota 4-banger, a tilted terror or a Cummins 6B. They're all different, but they're also much the same. You just need bigger tools for the Cummins.

N

 

[edgeman]

hey thanks very much for everyones help.

 

[edgeman]

Joe G , on the cummins database website they said somthing about sharpening the dowel rods then cutting a slit in the sharpened end of the rod, how wide of a slit are we supposed to cut. And how hard are we supposed to drive it in to the tappet before we lift the tappet. Dont want to ruin anything.

 

[Joe G.]

The details on the wooden dowels are on the web site I mentioned above.

 

[edgeman]

everything has been going fine, we got the cam out two inches but will not move anymore. can we try and force it without hurting somehting. We have turned it in circles trying to line it up right, all the lifters are off the cam what else can we try.

 

[Joe G.]

Remove the lift pump. The push rod in it rides on a cam lobe.

 

[edgeman]

Yup we figured it out, well after we wrote the post we went back out and played around with it, and eventually found out it needed to be taken off. So we are ready to replace and put it back together. I called the local Dodge dealer and the new case without the cover was close to $600. Is there anywhere we can get them cheaper. Please let us know. Thanks.

P. S. Joe G and everyone else thanks for all the help it was greatly appretiated, it helped us alot.

 

[tp0d]

dodge diesel timing, All matching items for sale.

There is a '92 housing for very cheap, I would venture to guess that it probably will not fit though.

However, there is a new housing at the end of the list for 119, that just may fit, the auction only mentions a part number, so you`d have to consult cummins on that one.

Someone here may have a deal on one, who knows. .

good luck

-j

 

[edgeman]

can anyone tell me torque spec for the two rocker bolts and valve cover bolts. Thanks

 

[Joseph Donnelly]

18 for valve cover and small rocker stand bolt. 120 for long head bolt/rocker bolt.