Cummins response:
Wow, I'm finally going to make a post over here. A friend of mine was just made aware of this problem at last nights San Jose RamRunner's meeting, and he decided to contact the "PowerMaster" himself (Cummins web site) to see what Cummins official stand was on the matter. I am going to repost the response for the TDR and I truely appologize if someone has already done so or I am passing on old info. I will also post his original questions as well. Here it goes:
Details:
Hi,
I own a 1997 Dodge truck with the 5. 9 Cummins engine. I recently heard from some other owners of the same truck/engine that there may be a problem with a dowel pin that aligns the front gear cover on the engine. What I was told is that some of the dowel pins are falling out into the gears and destroying the cover and causing the loss of oil pressure. There was also a mention of three bolts that are underneath the cover that tend to come loose. I have looked in the Dodge service manual and can't locate the dowel pin in the diagram of the cover and I am not clear as to what three bolts they were talking about either.
Could you please clarify as to whether or not this is something I should be worried about. I'm not sure if it is a problem that a few people had or if it's something that I need to be concerned with getting checked out immediately. If it's a problem I will take my truck to the local Cummins repair center and have them check it out. I just don't want to be on a long trip this summer and have a major mechanical breakdown, especially if I can prevent it.
Thank you for your time, I look forward to hearing from you.
Solution:
Thanks very much for your email messages on the Dodge/Cummins 6BT5. 9 timing gear cover to block dowel pin.
We have also heard about the TDR messages that customers have been sending in on this subject and a review of the dowel pin issue has been done by Cummins. This is how we know the issue today:
The locating dowel pin diameter from the supplier and the hole drilled for the pin, are designed to be 'press fit' dimensions. In some rare cases, the supplied dowel pin dimension and the drilled hole dimension, may not provide the correct 'press fit'. During assembly line manufacturing, it is impossible to determine the amount of 'press fit' between the dowel pin and the drilled hole, once the dowel pin is installed into the bore.
A few of the dowel pins have not had the correct 'press fit' in the drilled hole and have worked out of the hole, during normal engine operation. If the pin works itself all the way out of the bore, it can drop down into the gear train, which may or may not cause extensive damage to the gear train and gear cover. The percentage of failure is very, very low and does not justify a major campaign of all engines. If an unexpected failure should occur during the warranty period of the engine, the repair will be handled under normal Dodge warranty practices.
Since the Dodge warranty period for the diesel-powered trucks is 5 years or 100,000 miles, this issue would occur during the normal warranty period. A dowel pin coming out after this warranty period would not be considered a manufacturing defect.
The chances of failure was greatly diminished in early 1998 when the gear cover was changed to a 'blind hole' design, which would not let the dowel pin move out of the bore. If a Dodge customer has a great fear of this dowel pin coming out on earlier models, we suggest discussing the issue with your local Dodge dealer, to determine the appropriate action in each situation. In non-Dodge applications, the customer should contact the OEM dealer or the nearest authorized Cummins dealer or distributor.
The dowel pin itself can be replaced if desired or Locktite can be used to hold it in place, without having to replace the pin or gear housing assembly.
Inspection and securing of the timing cover dowel pin:
1. Remove the damper, pulley and gear cover from front of engine.
2. Tap on the dowel pin with a flat punch to insure that it is seated in the bore.
3. Clean all the oil from area with solvent and dry completely.
4. Apply some wicking type Locktite on the dowel pin and let the Locktite cure.
5. Reinstall the cover with a new seal and gasket.
6. Reinstall damper and pulley.
We hope this helps you better understand the dowel pin issue. We don't know about the three bolts you are talking about.
Thank you for your interest in Cummins power or products. Please let us know
if you need assistance in locating the nearest Cummins-authorized distributor or dealer. Please feel free to use our International Dealer Locator: (
http://www.cummins.com/partserv/intro.html) found on the Customer Assistance page of the Cummins website (
www.cummins.com).
Let us know if you have other questions, or if away from your computer, feel free to call us toll free at 1-800-DIESELS (343-7357).
Regards,
--
Powermaster
Customer Assistance Center
Cummins Inc.
Email: -- email address removed --
Ref: CAC ID
Attention: TDR Forum Junkies 
) at a place called "BUCKEYE WESTERN STAR" about 11 miles from my home. Found them on the Cummins site search. The local dodge dealer from me (about 5 miles from home) wanted more than double for the parts. 
