KDP fix Info needed

[AMorrissette]

Hi All,



I have a 95 Dodge 3/4 ton Cummins with 85000K and have completed a couple of tasks with help from all of you TDR members. Thanks! I first completed the fuel line replacement then the most recent, the starter selnoid kit fixed the starter and saved me $$$$ . Now I need information on the KDP (preventative matience) fix I have read alot of posts but no where can I find where to purchase a jig or find any pics of how to make my own. There are a couple of people here in Maine that would split the cost with me and we could have a KDP party. We have a friend with a 94 Dodge with 112K, KDP fell out an into the gears, he walked out of the local Dodge dealership with a bill of close to $3000

Has anyone heard of a recall on the KDP? If Cummins is so good why aren't they recalling this and utilizing the template that TDR members created??? Any imput on how I can fix my Dodge before losing my KDP is welcome and appreciated!!!!! You have all been a great resource in the past and I wanted to thank all of you for all the tips!!



Tony

 

[Joe G.]

Tony,



If you decide on the tab/washer method e-mail me at -- email address removed -- and I will send you the stuff I've collected plus the blow by blow instructions on doing the job.

 

[Bob Ellithorpe]

Tony,

Joe George was a great help to me when I did mine and I very much appreciated his help.

Both joe and R. ebel provided me with sketches/drawings of the washer/blocking tap and that also was a big help.

The only thing that I found when making the washer/blocking tab was that the distance from the center of the hole to the small end of the tab is fairly critical. It should be one inch or slightly less. if it's longer it will have interference and not nest right.

I had a piece of 1/4"x 9/16" flat stock that I made mine from and it worked out well.



Bob Ellithorpe

 

[AMorrissette]

KDP

Thanks, I'll let you know how I make out!!







Tony

 

[DieselB59]

The other thing is the CPFF dowel pin fix. Blue Chip Diesel and Auto Wurks Diesel have the jigs and perform the preventative maintenance for those who aren't willing to do the repair themselves, or are air compressor challenged.

 

[HomerDog]

For those who don't have the time or the mechanical skills/tools to do the preventive KDP fix, what would Dodge, Cummins, Auto Wurks, etc. charge for a fix??? When I asked my local cummins dealer, he said I would have some $$ invested for them to tear apart the engine to check the pin. . What do you all think??

 

[DieselB59]

That's the beauty of the CPFF dowel pin fix. Doing the fix is relatively a straight forward job. It is both proactive and reactive. It prevents a dowel pin from walking out, and in the event that it started to walk out, allows you to react before the bomb goes off. If in drilling, you can't go further, then and only then do you have to take the front cover off and go inside. What you have to remove to do the drilling is all required to be removed before pulling the cover off anyway, so why not go for what will cost less at first. If it has to taken further at least you're doing it for a reason and not just to take a look and see what's going on in there.

 

[HomerDog]

DieselB59--How much would Auto Wurks charge for a KDP inspection/Fix?? I'm just curious. I fly airplanes for a living. I would be pretty concerned if I was reading about a known defect in an engine and not much was being done to fix the problem.

 

[HomerDog]

DieselB59--How much would Auto Wurks charge for a KDP inspection/Fix?? I'm just curious. I fly airplanes for a living. I would be pretty concerned if I was reading about a known defect in an engine and not much was being done to fix the problem.

 

[AMorrissette]

CPFF,



Hi I talked to you last Saturday on the phone from Maine and you sent out the jig. Just wanted to let you know I received it Monday. I just completed the work on my truck, everything went great, the instructions and the pictures were very easy to follow. It took me a little longer on my truck as I have a hydraulic fisher plow so I had to contend with taking with taking off the hydraulic pump which is mounted to the alternator. I have notified the other Dodge owners that I have the jig and they are trying to schedule a convenient date that we can finish up all the other trucks. We can't thank you enough for supplying the jig and instructions to complete the KDP fix. You have saved a lot of people a lot of $$$$$$ !!!! As soon as we are done with the jig we will send it back to you. I wish that Cummins was as accommodating as you are cause we all belive that this is a defect in the motor and they should be backing up their reputation as a great diesel manufacturer. Thanks again!!



Tony Morrissette and the Bath Iron Works Dodge owners!

 

[HoleshotHolset]

Anybody want to send me the jig sometime?

Maybe we can do some at the NETDR meet on the 12th..... all we need is a few portable air tanks and the required haaaaadwayuh... . or hardware as the rest of the world says it.



Matt - KDP still at large... .....

 

[Bandit1]

what years does the KDP effect?

 

[cumminsgetme]

Bandit1,

When I first started seeing these problems it was mainly happening on the 97's, however you'll find that no particular year is excluded. Even the first gens are having problems with this, you can check my thread in the first gen forums. The cases that I have replaced were on a 94' and a 90 model cummins.

 

[R.ebel]

KDP blocking tab

The dimensions to make a KDP blocking tab can be found at this thread https://www.turbodieselregister.com/forums/showthread.php?s=&postid=188466#post188466

 

[Diver-Dave]

As I've aked on another thread, was just wondering if anyone has dimensions, exact drilling locations, drill bit size, drill depth or anything else that would enable someone to put in the fix without using the KDP jig. Or is this just too risky to try?

 

[Joe G.]

Dave,



Doing the jig type fix without the jig would be pretty iffy to say the least. I prefer the blocking tab method. It's more work, but you know for sure that it's fixed when you are done. With the jig type fix you are working on faith. Potential problems: you may miss with the blocking screw so the pin is not blocked, the pin may have fallen out and is rattling around in the gears already, the pin may have slipped and is in the way of the blocking screw, the blocking screw may cause an oil leak in the gear case, and chips from drilling and tapping fall in the gears. With the blocking tab method there is no sign that there has been any work done. The jig method is a LOT easier.

 

[Diver-Dave]

Joe G.



Have you done the tab fix? How long does it take? I've put in the GSK but it took me about 2 hours. Timing took me about 3 hrs. I'm guessing as an amatuer mechanic things take me about twice as long. Also, do you know where I can find instructions on how to do it?



TIA

Dave

 

[Joe G.]

Dave,



E-mail me at -- email address removed -- and I will send you the blow by blow description of the way I did it. Then you can make up your mind if you want to do that or the jig method.