kdp

[Killer223]

95 12V manual.
well it got me, truck was grandpas, then dads, then mine. has 1.3m miles on it. and it just now failed. dad thought it had been taken care of years ago when he put new injection pump on.
I have taken the cover off to verify, but something let go and I lost 2 gallons of oil in a customers driveway.
so what am I looking at to replace the gear case?
I know cam has to come out, injection pump comes off, etc. tappet cover doesn't leak as it was done when the new pump was installed, how long does this usually take, think it'll be a few days project, or will a fat man be able to get it knocked out in a day or so. or is it worth paying a shop?
any special tools?
anything else worth doing while I'm taking everything apart?
planned on new ac seals as there is a slow leak somewhere that consumes 1/2 can of 134a a year.
thoughts and knowledge appreciated.

 

[Joseph Donnelly]

You should get a valve job because of the high miles, and that will make it just a little easier to deal with the camshaft. However, you need some special tools and over all it is a big job. I covered it way back in the TDR, around Issue 40 I think, with a lot of pictures.

 

[BigPapa]

A friend and I replaced the gasket between the gear case and block on mine a couple years ago. It took us 24 hours over three days. I’d replace that tappet cover gasket while it’s down anyway. There’s no need to discharge the A/C, the condenser will swing out of the way.

 

[GCroyle]

A trip down memory lane for sure. Did this on our 97 back about 2008 and what an experience.

The only helpful hint I'll add that helped me a lot was a member from TN sent me a tappet so I could really create the fit and practice insertion and removal of the oak dowels that are used to hold the tappets up. Some might say, easy peasy I said gave me confidence in fit of dowels, it worked for me. I still have it I think and a few dowels have survived.

Oh yeah pulling that cam it's heavy an awkward to insert. I took a 2" ? pipe flange and a 10"+ length of pipe threaded onto flange and somehow bolted to to the gear. This made a lever/handle to get that war club back where it belongs.

Fun project.

Gary

 

[GAmes]

If you take the tappet cover off there is no need for the dowels. You can hold them up with cloths pins.

 

[BigPapa]

If you take the tappet cover off there is no need for the dowels. You can hold them up with cloths pins.

Or wrap a zip tie around them.

 

[BigPapa]

More better pics. We didn't have a problem handling the cam. Just need to be gentle so as not to ding the bearings. Also, don't drop the retainer in the oil pan. We were able to fish mine out with a magnet.

Gary's, y'all recognize Anthony, @acook?

 

[GCroyle]

Anthony came down to SC and we installed a clutch together in his truck. Then he demo'd burnouts with it to a group of customers on tour. Good times. He was a big help gave me a NOS gear case and advice.

A trip down memory lane. The truck was my sons first vehicle, we bought it broken due to KDP. It ran from 08-14 then he came back from deployment with SCANG and bought a real nice used Accord Sport. Dealer took the 3500 in trade with a grin.

 

[GAmes]

Gary's, y'all recognize Anthony, @acook?

No. Too long ago.

 

[Killer223]

I appreciate the responses. after taking it over with my bride, this will become a winter project. I'll pull the engine and rebuilt it fresh, everything that needs to or could need replacing will be.
thanks again for the info.

 

[Cummins12V98]

Can't wait for a write up and pics of that project!!!

 

[Joseph Donnelly]

My article was in Issue 33, p. 46-48, August 2001.

 

[Rosie the rustbucket]

I am a noob to the 12v family. I just got this 97 truck that has no less than 300,000 miles (instrument cluster was DOA other than oil pressure but that's another subject) and was going to ask about high mileage trucks and the need to verify the KDP fix... Is the jig still a worthwhile way to do the repair? If so, are they still available for love or money?

 

[BigPapa]

If you’re unsure about it, I’d definitely make check it out. Personally, I would pull the cover.

 

[GAmes]

Is the jig still a worthwhile way to do the repair? If so, are they still available for love or money?

It has been discovered since the jig days that the case retainer bolts also work loose at times. So along with tabbing the dowel pin it is also recommended to remove, clean and loctite the bolts. There are five.

 

[Rosie the rustbucket]

If you’re unsure about it, I’d definitely make check it out. Personally, I would pull the cover.

Thanks, I saw the kit Genos has with the link to the tutorial.

 

[Rosie the rustbucket]

It has been discovered since the jig days that the case retainer bolts also work loose at times. So along with tabbing the dowel pin it is also recommended to remove, clean and loctite the bolts. There are five.

View attachment 141326

Thanks for the picture. And thanks to you and BigPapa for the advice. Better to do it rather than sweat it.

 

[GAmes]

Thanks, I saw the kit Genos has with the link to the tutorial.

I like Genos, a lot, but there is no need for a "kit". The metal tab on mine is a piece of aluminum cut from a beer can. Besides a new seal it would be advisable to also install a new cover gasket. A Felpro gasket and seal kit (FEL-PRO TCS46001) is about $40.

 

[Joseph Donnelly]

I would use a tab thicker and stronger than a piece of beer can. Use a longer bolt if needed.

Of the 5 bolts, you can get on 4 directly and remove them. The fifth is hidden behind the cam gear and not in line with one of the windows, so I just tighten it with a bent open end 10 mm wrench.

 

[GAmes]

I would use a tab thicker and stronger than a piece of beer can. Use a longer bolt if needed.

Why? There isn't any force behind the dowel pin pushing it out.