Engine/Transmission (1994 - 1998) KDP tab importance!

[CSnyder]

Heres a picture of a 12 valve KDP that is just about ready to fall out. This is on a local customers daily driver that had a front seal leaking about half a gallon of oil in 500 miles. He is feeling very fortunate that he had me do the wrenching instead of the dealer. I cant stress enough how important it is to get yours tabbed if it hasnt been done yet. This one here if you look closely is shiny from spinning in the hole for some time. I simply grabbed it with my fingers and pulled it out and slid it right back in!

 

[Fordiesel69]

I would like to do mine, but don't know how to obtain a jig. The sticky on this website is dated 01, so I don't think any of the member are still activly loaning them out.



Is it possible to remove the front cover and simply pull it out and fill the hole with silicone?

 

[USMCBay]

WOW... makes me want to tow mine home to fix it.



Yea... the jig? Does anyone have the jig?

 

[GCroyle]

I'm a believer.

We just fixed a 97. If you can get the cover off, you can put the pin in and make a keeper out of some flat stock to hold it in place, use a longer bolt also. Takes a bit of patience for the repair, but nothing impossible. I'd try to keep the pin in the gear housing.

 

[Joe G.]

Emal me at -- email address removed -- for tab instructions.

 

[surfbeetle]

TST Products, Inc. has a kit for 50 bucks, comes with everything you need (except your tools). If you are in the same boat as the photo above, then you can do it with out a jig.

 

[Wedge]

TST Products, Inc. has a kit for 50 bucks, comes with everything you need (except your tools). If you are in the same boat as the photo above, then you can do it with out a jig.

I just got a #6 fuel plate from TST with a KDP kit at a discount. The've got a package deal going right now. I figured if I'm going to fix the dowel pin that I'll need a crank seal and and a few other things so if I spend the money on their kit I won't have to fab anything and probably save time.

Here's the link w/fuel plate:

TST Power Kit without Video with KDP Kit - KDP 03 & IN

 

[Fordiesel69]

Why can't we remove the front cover and discard the dowel pin. I thought it was for assembly purposes at the factory. I can't imagine why you still need to leave it in.

 

[Dave M]

Why can't we remove the front cover and discard the dowel pin. I thought it was for assembly purposes at the factory. I can't imagine why you still need to leave it in.

I used the TST kit to tab mine a few years ago. I remember when searching on KDP that this statement came up. From what I remember, the feeling was that leaving the pin in would provide more support for the case. Adding the tab over the pin is no big deal especially with the TST kit that has the tab and the longer tab bolt.



But it is a good question. The newer design gear case has a blind hole that covers the pin so the pin cannot come out.

 

[Joe G.]

There is a lot of weight on the gear case because it supports the P7100 injection pump and positions it correctly. I have heard of gear case gasket problems cause by not having a dowell pin. Replacing that gasket is a BIG job.

 

[Bob V]

Thas is why the jig method is not a good idea! If someone jiged this one it would most likely knocked the pin onto the gears. The tab and the seal is available at Cummins for a lot less than $50. 00. The front gasket will most likely be fine with a light bead of silicone.

Part # and 4 year old prices for a '97 5spd

Seal 3804899 ($28. 80)

Gasket 3918673 ($23. 05)

Tab 3958017 ($1. 00)

 

[Breed]

I did my truck a couple of weeks ago using the TST kit also repaired the vacuum pump seal from Gould and I am thrilled with the two kits, both were well explained and fairly easy to do. I had one bid from a shop for $600. 00 just to do the vacuum pump seal. I would really stress to repair the KDP it's just not that difficult or expensive.

 

[bmoeller]

Glad you found that one Chris. Wouldn't have been long. Mine was sticking out about an 1/8" or so. I didn't use a tab. Just used a small punch and peened the hole to prevent the pin from moving. Front seal got replaced at the same time. Mine also came with a dust seal. Went ahead and used it since I'm around a lot of dirt.

One other thing to check with the cover off is the inside case bolts. Mine were all loose. Loctited them.

 

[CSnyder]

This guy was absolutely thrilled that he met me at a farm sale last week and started talking Cummins with me when he seen me get out of my truck. His dealer quoted him 650 dollars for the front seal repair. . LOL! He had an appointment scheduled with his dealer but we all know the dealer would have never checked that dowel pin. I showed this guy some pics of what happens when they drop and break the cam gear and housing and he was in total shock. I didnt charge him any extra to tab it and retorque the inside housing bolts either and he was so happy about it he left me a 50 dollar tip. I think Ive gained him as a lifetime customer now. Last night he called and asked about having his trans rebuilt (I explained Goerends trans to him while he watched me work) and he also wants to go Amsoil bumper to bumper.

 

[ZBrown]

makes me feel stupid for not fixing mine yet... .



arent the very early trucks a little less prone to this?

 

[Joe G.]

As far as I know from reading on this and other forums, no particular year 12 valve is more likely to have the problem. It's a easy job to tab it. If yours falls out it's NOT an easy job to fix.

 

[holmanrd]

A word to the wise. (I sure wasn't, even though I knew the risks) Fix it or pay to have it fixed ASAP. I put it off and when it did go, I didn't have the time to fix it so I had to pay $3000. 00 at my local shop to have it fixed. Don't put it off. Robert

 

[bigtoy]

the first gens. with the VE pump are less prone to the KDP. Less weight and vibration than the P7100. But it still happens! A friend of mine had a 91 that he sold puked the KDP a couple months later.

 

[Missouri Mule]

What I have read 89 to late 99 are prone to it.



You can see what a tab method looks like in this thread plus some KPD damage.



https://www.turbodieselregister.com...ission-1994-1998/182277-killer-dowel-pin.html



Joe G innstructions are good ( I used them) but TST has more photos.



http://www.tstproducts.com/DowelPina.pdf

 

[LeverB]

KDP Repair

Cummins is doing mine wednesday for $300. An honest shop?