Engine/Transmission (1994 - 1998) KDP Tab Install Instructions

[jacqnbill]

I need install instructions for the KDP tab procedure. I have searched this forum and emailed Jgeorge per the FAQs but no luck. Thanks in advance.



Bill Davis

 

[LDPetersen]

I did mine over a year ago. Cleaned the garage and must have thrown it out. Mine was the TST kit. Had very good instructions, but I guess I can't help you. Larry.

 

[bmoeller]

If you get the kit from TST ( https://secure.tstproducts.com/acatalog/TST_s_Products_Replacement_Stock_Parts_25.html ) , it will have the instructions.



TST kit does NOT come with the gearcase cover. Cummins P/N 3918673 is the one that I bought from Cummins Great Plains. 'Bout $25 and change.



Otherwise-

Originally posted by R. ebel

If your game to check on your dowel pin here you go... ... ... .





Timing Cover

Service and Repair



REMOVAL



1. Remove fan drive assembly.

2. Remove the fan belt.

3. Remove belt tensioner.

4. Remove oil fill tube and adaptor.

5. Remove vibration damper.

6. Remove the bolts that hold the gear cover to the gear housing.

7. Gently pry the cover away from the housing, taking care not to mar the gasket surfaces.

8. Clean the old gasket residue from the back of the gear cover and front of the gear housing.



INSTALLATION



1. Lubricate the front gear train with clean engine oil.

2. Thoroughly clean the front seal area of the crankshaft. The seal lip and the sealing surface on the crankshaft must be free from all oil residue to prevent seal leaks.

3. Apply a bead of Loctite 277,or equivalent to the outside diameter of the seal.

4. Install the seal into the rear of the cover using a plastic hammer and the alignment/installation tool provided in the seal kit

to prevent damage to the seal carrier, hit the alignment/installation tool alternately at the 12, 3, 6 and 9 o'clock positions.

5. Install the pilot from the seal kit onto the crankshaft.

6. Using the pilot as an alignment tool, install the cover and a new gasket.

7. Install the cover bolts and tighten to 24 Nm (18 ft. lbs. ) torque. Remove pilot tool.

8. Install the oil fill tube and mounting bolts. Tighten the bolts to 43 Nm (32 ft. lbs. ) torque.

9. Install the vibration damper. DO NOT tighten the bolts to the correct torque value at this time.

10. Install the belt tensioner. Tighten the mounting bolts to 43 Nm (32 ft. lbs. ) torque.

11. Raise the belt tensioner to install the belt.

12. Tighten the vibration damper bolts to 125 Nm (92 ft. lbs. ) torque. Use an engine barring tool to keep the engine from

rotating during tightening operation.

13. Install the fan drive assembly.

 

[bmoeller]

"A" is where the dowel pin is to be.



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[jacqnbill]

Thanks for all who responded. I ordered the TST kit. Thanks again for your help.



Bill

 

[RT66DOC]

Originally posted by jacqnbill

Thanks for all who responded. I ordered the TST kit. Thanks again for your help.



Bill

Worth every penny.



Might want to check your water pump while you're in there - won't get any easier to change than that. Mine was OK at 100k but I put a new one on and kept the old for a spare. Also just as easy to put a new serpentine belt on as to reinstall the old one. My . 02.

 

[jacqnbill]

KDP Inst

Originally posted by RT66DOC

Worth every penny.



Might want to check your water pump while you're in there - won't get any easier to change than that. Mine was OK at 100k but I put a new one on and kept the old for a spare. Also just as easy to put a new serpentine belt on as to reinstall the old one. My . 02.

Thanks and good advice. I understand I should check idler bearing also.



Bill

 

[RT66DOC]

Idler bearing - yesss. Found out about that a few days after I got it all back together.

 

[Joe G.]

I just responded to Bill's request by e-mail. I was called out of town for a few days by some steelhead in Oregon.

 

[jacqnbill]

I installed the TST KDP kit today with no problems. I removed the drivers side battery and upper radiator hose and completely removed the Windshield washer resorvoir. This made the removal of the fan shroud and fan assembly a piece of cake. Only lost a pint of blood. For those keeping tabs the Dowel Pin was completely seated with no movement.

1998 12 Valve 4x4 #10 TST plate, 16cm turbo housing, 60,000 miles. Thanks to Joe George who cut his fishing trip short to respond with instructions and to all for the help.





Bill Davis

 

[hbowers]

5 bolts inside cover

there are five bolts inside the gear cover that imo should

be taken out,cleaned and loc-tited also while you're tabbing

the dowell pin. one of those bolts is about as apt to fall out

as the dowell pin. especially on high miliage 1st gens.

but I understand Cummins didn't start loc-titing those bolts

until 96. so speaking for myself, I am going to take care of

the bolts when I tab the dowell pin. Harold

 

[MUDDY]

here is some carnage pics from the 92 harold did

:{



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and the bolt that fell out and caused all this carnage

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[LDPetersen]

kdp and bolts

Did my 95' 2500 about a year and a half ago. Pin was part way out, and SEVERAL BOLTS WERE LOOSE. I would not take a chance with out doing the bolts also. Guess this is why.