Engine/Transmission (1998.5 - 2002) KDP kit ??? Help!

[TPringle]

I have the front off my engine to fix some small oil leaks, incl. the side cover gasket. I ordered the KDP kit from Genos. To be blunt, it doesnt fit! The kit has the angled tab, which should be right for this engine. The engine has about a 1/4" raise where the pin sits (the bolt for the tab is 1/4 lower then the dowel pin hole). The only way I can get the tab kit to fit anywhere near right is to add 2 small washers on the bolt between the tab and the gearcase. I dont like this! Even with the locktite, I could see that moving or backing out.



I dont know how to tell of this has the "fixed" housing or not. The pin was below the surface by at least 3/16", when I hit it with a punch, it felt tight. It looks like it has a ream (small ridge) or something on top of the hole, yet I cant really catch a small screwdriver on it.



I called Geno's to question this, they said to put a washer under the tab and they hadnt heard of this before. I did as they instructed, but feel uncomfortable with this. If it fails, there goes my engine. I dont want to cause a problem by trying to prevent one. Anyone else dealt with this?

 

[Vaughn MacKenzie]

What year of 24-valve do you have? It is pretty rare for a dowel pin to come out especially 2001 & later, I have heard of it happening to a few '98-99s.

By the way does it look like this one- this is a first Gen 12-valve though http://www.dieselbombers.com/1st-ge...9-93/35885-killer-dowel-pin-question-pic.html

 

[JLandry]

Tim,



My truck had the same setup. I think what we have is the modified gear case Cummins came up with to eliminate the KDP problem. The extra "rise" of material around the dowel pin and the projection under the gear cover (take a look) will prevent the KDP from coming out, so in theory no tab is needed.



Just to be extra safe, I went ahead and made my own longer s-shaped tab which goes up and over that rise of metal and it's fastened directly under the bolt head (with Loctite). It's been 3 years and 35,000 miles with no problems yet.



Best regards,



John L.

 

[TPringle]

This MAY be the modified gearcase. The truck is a year 2000, with quite a few miles, and nothing seems to have moved.



View attachment 79930



This is what I did, I added 2 small washers under the tab, and locktited everything. Still not very happy. I'd almost rather take a chance on the pin!



View attachment 79931



I could try to "ding up" the inside of the bore for the pin a little and shove some locktite inside. I just dont want this to come apart and do the damage that I am trying to prevent! What do you think?

 

[TPringle]

Here's what I came up with. I was concerned that the bolt and washers could work loose and end up causing the exact problem I was trying to prevent, so I removed the tab. I was surprised that it was as tight as it was. The loctite did a good job, so it probably wouldnt have moved at all, even with the 2 washers. I did loctite the washers too.



View attachment 79976



I used a small center punch to "knurl" the bore, then shoved some loctite in. I really dont think it will come out. I suspect this is the improved gear housing, but havent had onyone confirm this yet.

 

[hbowers]

kdp kit

you have the revised gear case. it has a stepped hole(outside of hole is smaller) pin can't come out. no tab is needed.

 

[MLee]

If its a newer case then you wont have the engine data tag on the side under the pump.

Unless some one took the time to put it on there.

Its to bad that information on this kind of repair is not forwarded some how.

 

[hbowers]

so far I have removed the front cover off of 2 02's 1 01,1 2000,8 99's and 1 981/2

all of these had the revised gear case. but I have seen 3 981/2's w/ the old style gear case. I wish there was some way you could tell without removing the cover.

 

[jclark5810]

My 93' has a "stepped" cover like that, does that mean it's "revised"? When i did the kdp on it i also just used some washers and loctite since my tab was straight. I still feel uneasy but it i'm sure it'll be fine.

 

[hbowers]

no it does not mean it's a revised case. 1st gens(89-93) had cases that looked like the one in tpringles photo. but the hole for the pin is same size all the way. the pin can and has fallen out of who knows how many 1st gens. also cummins didn't start loc-titing the 5 bolts inside until 96 I think. so especially on 1st gens a bolt is just as apt to fall out as the dowel pin. so you need to take the bolts out one at a time clean and loc-tite them. TST products sells tab kits for 1st and 2nd gens. I do also. ist gen tabs are bent to fit.

2nd gen tabs are flat. I'll post a couple pics if I can .

 

[jclark5810]

Thanks for the help. Yeah I ordered my kit from TST and the tab was straight. I just tried to make do; i did however tighten the bolts.