Engine/Transmission (1994 - 1998) kdp on a 96

[hbowers]

I just finished tabbing the pin on a 96 w/207kmi. some people think if it's gone 200k it aint gonna fall out. here is a pic of what I saw when I removed the gear cover.

 

[hbowers]

I just finished tabbing the pin on a 96 w/207kmi. some people think if it's gone 200k it aint gonna fall out. here is a pic of what I saw when I removed the gear cover.View attachment 87938

here is a better pic I think

 

[Missouri Mule]

Looks like you caught it just in time, another 50,000 and it would beenout all the way.

 

[JR]

I have to yank my radiator for some cleaning and replace my damper this spring and I am going to take a look at mine just for peace of mind. Would hate to be 500 miles from home and have a catastrophe. I've heard conflicting stories, some say the problem was 12 valve related only and some say the first few years of the 24 valve could have been affected, I'm going to have a peak.

 

[MLee]

First part of 98.5 was urged to do the KDP. There has been a few cases that had 2002 that dropped the pin. But the new gear case with the knurled edge in most cases took care of the pin problem. Do it just to be safe. Its just a four hour job and what better way than to show some TLC for your ride.

 

[hbowers]

the pin was so loose I'm surprized I made in my shop.I pulled it out w/ a magnet. so far I have checked 18 98.5- to 02's and just three of them had old style cases. those three were all 98.5's. three out of the 18 were 02's

 

[MLee]

Its pretty important that the pin is in place, to help keep alignment of the gear case where it should be. Just ping it in place and tab it. make your own tab from a fender washer like the original tabs were done. not much cost involved, just the labor to do so.

 

[Joseph Donnelly]

Were the 5 bolts still tight?

 

[Cosmo]

Fender washer, or just use an un-insulated electrical ring terminal.

 

[MLee]

Fender washer, or just use an un-insulated electrical ring terminal.

Never thought about this electical ring, but everybody here has used something a little more substantial. A 1/4 fender washer just needs to be drilled out a little for the bolt, and then shaped to fit the space. From the center of the hole you need 1 1/4" length (at least) to cover the pin, and then shape the rear to bourder the bolt head. We also used a bolt a little longer, recommended by Joe Donnelly.
As mentioned above by Joe D, make sure you check the bolts in there, They can cause the same problem. 18' llbs of tourqe, not much but clean and use thread locker on the bolts that can be removed.

 

[Cosmo]

Yeah I know everyone uses big burly pieces of steel, but I had a ring terminal handy and it's subject to approximately zero force...

 

[hbowers]

yes joe the bolts were tight. they had some kind of thread sealer on them.

 

[KEnglish]

Just did mine today. Joe emailed me the instructions back in 2004. How's that for being lazy, and lucky.

 

[GTSimms]

Just finished doing ours yesterday, used the TST kit which I had purchased sometime ago. Did this before our trip to the South with the Lance camper also replaced hoses and new Cummins Complete coolant. For a birthday present to myself I had purchased Gear Wrench serpentine belt tool kit, made the belt so much easier to remove and replace it will stay in the truck as part of the tool kit also from Genosgarage had purchased their hose clamp tool that worked great too. Truck is 1997 3500 4X4, pin was out maybe sixteenth of an inch, also did the bolts too. 80,000 on truck. Thanks to all here for commenting and pushing me to get this done.