KDP this weekend. Advise?

[BCFAST]

Will be doing the tab repair I got from Rebel this saturday. The project is a little scarry as Im not a pro wrench. I can do a plate and injectors by myself, but this seems a whole lot more complicated! Is there a chance that the cam timing has slipped as a result of a protruding or bent dowel pin? If so, how do I time it? are there marks on the gears? What else can you guys think of that I NEED to know before I tear apart my only means of transportation?



Brian

 

[Rammin On]

I doubt very seriously if the cam has slipped in the gear ... they are a bear to remove. If any timing has slipped ... the pump shaft can slip in the gear. I wouldn't worry to much. The worst part is getting the fan off ... once you get past that ... tis easy. If you are putting a new front seal in ... . that's fun too . . just take your time and all will go well ... Have fun!

 

[DMAC]

I did my KDP last weekend and it was not to bad, make sure you have 2 of the crank seals cause they are a PITA to put in. Once you have the fan and shroud out it is very simple to get to the cover and remove it. If the pin fell out you would most likly know due to the gear case being cracked and leaking oil, I was suprised at how big the pin is. If you have any more guestions let me know and I will try to help.



mac

 

[RHARVEY]

Another problem is the nut that holds the fan on!!!! Make sure you have a long chiesel so that you can get it off. It's left hand threads(loosens toward the drivers side), so a couple of smacks with a hammer with the chiesel set on the shoulder it will come right off...



Rick

 

[BCFAST]

Is the crank seal replacement an option? How will I know if it's in need of replacement? I am going to Cummins today to get the parts... .

 

[DMAC]

You will need the crank seal, once you pull off the gear case cover you have to replace it get 2 just incase you mess up the first one which can happen. Also get some brake cleaner to clean the shaft and get silicone for the gasket on the cover.



mac.

 

[RHARVEY]

Since you are going to be there... do it!!!! Its easier to do the crank seal when you have the cover off where you can work on it. Just take your time when putting the seal in the cover. . it took me a few minutes to get it to start flat.

There will be plastic tool that slips over the crank(bell end toward the block) to align the seal over the nose. When you get the cover pushed back against the block. . you can take a pair of pliers and pull the plastic tool right out. Also make sure the seal is DRY and clean before you slide the cover back over the crank. . it has to be dry to seal.

Have fun with the job... . Just take your time and clean all the gasket surfaces...



Rick

 

[DMAC]

BCFAST!

I just pm you. Oo. Oo.

 

[JWRowe]

kdp

BCFAST, While inside torque all the gear housing bolts you can reach. They, as well as the cover bolts when you put them back in, should be 18 ft. lbs. , fan hub bracket mounting-18 ft. lbs. , fan pulley to fan hub-7 ft. lbs. Service manual calls for 92 ft. lbs. on vibration damper bolts and 42 ft. lbs. on the fan mounting/fan hub. I have had several of these off and if you tighten it hand tight then use a large drift and 2 lb. hammer to seat it with a couple of good tunks you should be fine. This will tighten a little as the engine turns.



Good luck, John

 

[RottnDogue]

Shouldn't have to take the Fan Shroud off at least we didn't.

 

[HoleshotHolset]

When doing the tab-method... . removing the shroud gives you a lot more room... . and allows you to take the fan out the top, which has to be removed to get the gear case housing/cover out of there.



Matt

 

[QRTRHRS]

Brian, If you can do the injectors and plate, you can handle the tab. Even with a fan wrench, mine was giving me trouble so I pulled the four bolts holding the bracket. Slip a piece of cardboard in front of the radiator for protection regardless. I cleaned and put Locktite on all my bolts. Having the fan shroud out gives you more room for that. My pin by the way would not go flush. I put a slight "S" bend in the tab so it would not be "torqued" due to not laying flat.



I bought a pin and a spare seal to have on hand just in case. Not interested in parting with them but would gladly help anyone in need on a sunday. Anyone close can email ahead of time for my phone number just in case. I happen to be hit or miss checking emails on weekends. No sense in everyone having all these extra seals on hand.

 

[BCFAST]

Had some daylight..

... so I got started this evening! Will be getting off work around 12 noon, and am comming straight home to do it while Cummins store is open! Tonight I got the fan off (5 minutes), got the fan shroud out leaving the washer bottle in the truck and taking the overflow bottle with the shroud (15 minutes). Got a nice head-start on tomorrow's fun. At your recommendations, I got 2 seals, one gasket and a tube of Cummins goo for the gasket. If I get stuck, I'll be on here! DMAC was kind enough to give me his phone # and I chatted with him about the procedure... . he was very encouraging... thanks, buddy! How about that TX hospitality?!

 

[_Hyde]

First post on the valve challenged forum in a while!

Beware the oil pump bolts! They torque to much less than the cover bolts for a darn good reason. If you torque too tight it breaks the corner off. Been there done that. I also recommend throwing away the bolt that is replaced when installing the tab. Went on a wild goose chase for the missing cover bolt only to find that it was an extra. Oooppsss! Oh well, live and learn die and forget it all. Hope this helps.



Darren

 

[GOTSOOT]

KDP

Why go to all that trouble-use the jig method 1 1/2 to 2 hrs and your done. why take something off that is not giving you any problem. my $0. 02:--)

 

[Deezul1]

When installing the seal it goes in from the back side if the cover is off, easier too. If you have a drill press it makes a great arbor press to press the seal in.

 

[BCFAST]

Thanks Everybody!

Got it done in about 4 hours. The seal install sure is frustrating... but the rest wasnt too bad afterall! BTW, my KDP wasnt out at all!!!Oo. Glad it's tabbed though. Am going for a drive to make sure the crank seal is OK... . again, thanks to all with your wisdom.

Brian

 

[Tim1]

Hi second gen guys,snuck over here for a few, a couple pieces of allthread to use as guide rods when installing the outer cover really helps! Tim

 

[nfox]

kdp fix

Do i have to pull the radiator out to preform the kdp fix? Where can i purchase a stainless steel tab and how much would it cost? Does any one have a step by step instruction on this repair? I'am a little nervous about doing this? _______________ 96 5spd 4. 10 ls diff dana 80 rear milled camplate wastegate blocked 4" exhaust turbo to tail lost cat and silencer ring in windstorm somewhere 305-70r-16 goodyear at-s.

 

[Jim Fulmer]

Since Joe George hasn't chimed in here I will, E-mail me -- email address removed -- and I will send you the instructions I got from him.



Jim