kdp back Issue ?

[RSeymon]

This Green wrencher is going to try and kill my dp, Can anyone advise if there is a back issue with step by step guide to how to access front cover and what special tools if any required. Have read most of all the posts on kdp but need some help,



Thanks in advance

 

[RSeymon]

kdp back issue

If anyone has issues 37 and 38 there might be articles of help. If anyone could email me those articles would be of great help



Thanks in advance

 

[cerberusiam]

The only special tool will be a wrench big enough to fi tthe fan nut and possibly a chain wrench to hold the fan pulley. It is left handed and if its never been off its a bugger to break loose.



Pull the fan off and pull the shroud and fan out.



Undo the strap holding the oil fill and just twist it around part way to remove.



The damper pulley does not press on. Four bolts hold it on the crank and it slips off. Might have to tap it a bit to get it loose.



I believe there are fifteen bolts around the front cover that hold it on. Clean things up and look close and you should see them all.



might have to take the fan pulley off, don't remember.



The biggets hassle is getting a new seal in the front cover.



Hope this helps.

 

[LarryWard]

That chain wrench does chew up pulley edges, especially when hammering wrench in wrong direction. The nut comes loose clockwise as you stand in front or as I remember the same direction as fan turns. Had to take file to clean up pulley edges. Also, it took a little time to figure out how to use the clear plastic sleeve but trying to get the seal to slide over shaft worked great once you slip the large end into seal and then it goes right on without damaging it. Tried to put cover (with seal in it) on and it just was not cooperating. So I tried that sleeve that came with my seal (no directions). We also made a couple short studs to help align cover till we could start installing all the bolts of which there are about 4 longer ones that will only work in there original places. I was definitely glad we did not do the jig method. The dowel had moved out 1/4" and some of the case bolts were not very snug. Also discovered the idler bearing sounded very dry so will need to replace it soon. Plus at 215k I think a new seal was a good investment. I suppose this has been well covered before.

 

[Bob Beauchaine]

Remember there are 5 10MM bolts inside the front gear case cover that should also be tightened. I have seen a camshaft broken into three pieces when 1 backed out and jammed between the cam drive gear and the crank. Four of the five can be removed cleaned, loktited and reinstalled. For the fifth you will need to bend a 10MM wrench to about a 45 degree angle, loosen it, clean it then loktite and re-tighten.



Good luck

Bob