KDP

[RedD250]

I'm about to do my KDP using this video tutorial: (This guy and DecentGarage are both excellent sources for video tutorials on these trucks. Very well done videos. Filming is great, and they take the time to explain everything thoroughly. All the other first gen videos out there are just terrible. The guy either can't form a cohesive sentence without profanity, or doesn't know how to hold a camera properly, out of focus, blurry, no explanation of what's going on, missing information, etc.. That, or they are just 10+ years old and filmed at a terrible low quality resolution, rendering them useless.

And these instructions: https://www.tstproducts.com/DowelPina.pdf (If this link has to be removed due to it linking to a parts seller, the video tells you where to get them from.) Seems to be very comprehensive.

Does anybody have any additional input from their own experiences? I have heard people talking about bending a 10mm wrench to make it easier to get at some of the bolts, can somebody post a pic of it so I have a better idea of how to do it? I don't have a vice or a torch, so I'm going to have to have a friend bend it for me. I will be getting the engine barring tool, will this prevent me from having to modify the wrench?

What is the correct seal installation tool for the crank seal? Using a punch like the guy in the video did scares me. I'll botch it for sure.

The above instructions and video don't mention removing the radiator, but I have heard that makes it much easier. What about the intercooler and a/c condensor? Should those come out as well? If so, what surprises am I in for there? Do I need any special tools to get the a/c and transmission lines disconnected?

Thanks!

 

[-gtsm-]

Disappointing you have not got any response to your questions . I just ordered everything to do the KDP repair , my Tappet cover leak , my A/C service , spare tire and transmission and fuel filters . I don't think the seal installation will be as tough as you think ... I've installed those type seals before and as long as you tap them in easy and straight you will be ok , I have a seal driver now but I've used big sockets in the past to tap them in .
I'm going to remove my radiator to do mine ... but my a/c condenser is already discharged and my truck is non intercooled so not as much downside for me. I don't know which bolt the bent wrench is for so I can't help you there ... hopefully someone will chime in on that , I've been going through old issues of the TDR but haven't come across the bent wrench in any KDP articles yet . I'm at sea right now with ****ty internet . Tough to do do research or watch you tube . Good Luck

 

[sdeeter19555]

My thoughts, having done this several years ago, is forgo the tab and simply stake the pin into the hole with a chisel. The fitment of the pin to its bore is tolerance (it is not sloppy loose), any deformity at the bore entrance would prevent that pin from ever coming out. No tab to buy or make.

Back every bolt out, clean them and their bore, and reinstall with loc-tight. I found three of mine finger tight which was the source of my gasket weeping.

If you install a new crank seal, they install dry...do not oil or they will leak.

 

[RedD250]

My thoughts, having done this several years ago, is forgo the tab and simply stake the pin into the hole with a chisel. The fitment of the pin to its bore is tolerance (it is not sloppy loose), any deformity at the bore entrance would prevent that pin from ever coming out. No tab to buy or make.

Back every bolt out, clean them and their bore, and reinstall with loc-tight. I found three of mine finger tight which was the source of my gasket weeping.

If you install a new crank seal, they install dry...do not oil or they will leak.

Good to know. I'd have oiled it for sure. Thanks!