Engine/Transmission (1994 - 1998) Problems with TST Power kit installation

[JamesPhillips]

I attempted to install a #8 plate from TST this weekend. I was watching the video and reading the printed instructions while performing this power upgrade. Everything was going fine until I tried to remove the breakaway bolt in the AFC housing. I performed this task just as the instructions indicated. I used a Torx #15 with my hand impact tool. All it did was strip out the head. I then obtained a #20 Torx bit and tried with the same results. I decided I'd better stop before damaging the pump. I put everything back together and decided to write to the masses for help. My thought now is that I should purchase a bolt from a Dodge service department before trying again. I think I may be able to get this bolt out with a chisel. If that doesn't work maybe an e-z out bit (I don't really want to do this for fear of damaging the pump). I may have to remove the fuel lines to access this bolt which I don't want to do either. Any suggestions would be greatly appreciated.



Thanks,

James Phillips



96 CTD, 2WD longbed, ext cab. 140K miles

 

[ata]

It`s fairly easy to get it out with a chisel. That`s how I got mine out.

 

[DSiemens]

I used a small sharp chisel too. Take your time and you should not have to remove lines. However, if you decide to remove the lines, remove them as whole unit. Also get plastic protector caps from a inj. pump shop. You don't want debris getting into the pump or injectors.

 

[Howard Durand]

Removing the fuel lines is not that much of a deal and it does make it easier to get to the bolts.

A small chisel can be used to unscrew the breakoff bolt or possibly a square easy out if the hole has been enlarged.

If all else fails, drill the head off with a large bit then when you get the housing off, unscrew it with a pair of vise grips.

You would have to get pretty careless to damage the pump housing.



New bolts can be bought at any good hardware store.

For the two upper bolts you need M6 X 1. 0, 16 mm long.

The lower bolts are M6 X 1. 0, 25 mm long.

 

[bighammer]

I also removed the screw with a chisel. If you tap on it straight in towards the center a few times, (enough to make a dimple, but not so hard that you bend or knock off the head) then move the chisel to loosen it using the dimple.

 

[bighammer]

I also removed the screw with a chisel. If you tap on it straight in towards the center a few times, (enough to make a dimple, but not so hard that you bend or knock off the head) then move the chisel to the side so the taps loosen it using the dimple. Once broken loose, a torx or pliers might work to remove it.



(this makes sense to me, I hope it makes sense to you)

 

[JamesPhillips]

Thanks everyone. I'll keep you posted on my progress. I probably won't be able to get back to this until the weekend.



James

 

[Howard Durand]

Bighammer,



That makes sense.



Once you have a cut or dimple in the head, use a thin bladed screwdriver to tap it aroung instead of the chisel.

Less chance of cutting a divot out of the head.

 

[HEMI®Dart]

This works GREAT:



Get a long 1/8" drill bit and drill the break off screw head about an 1/8" deep. Then drive a #20 torx bit into the hole.



The torx bit really bites hard with the 1/8" pilot hole. In fact my #20 torx bit still has a breakoff screw stuck on the end of it.

 

[bmoeller]

I had to take my fuel lines off and use a chisel. The Torx bit was a piece of junk (mostly due to the fact I couldn't hit it straight on because of the lines). Couldn't get the chisel in there either. Just used a dull one that I hadn't sharpened yet. Worked great.

 

[radixr]

I second HemiDart's suggestion. I tried a Torx bit without drilling a pilot hole and got nowhere. With the pilot hole, it was a snap. Oo.

 

[Neibe]

Chisel works good my cover has only had 3 screws in it since I started monkeying with it so I can tweek it a little bit more. Another trick to try is to take a punch and hit towards the outside of the screw in a direction so as to loosen it. Take the punch and strike straight down on it to make a dimple in the head then angle the punch in the loosening direction and strike the punch with a hammer.

 

[pm720]

One of those spring loaded automatic center punches works great on stuck bolts too. Used on several times with good results.



Scott

 

[JamesPhillips]

#8 Plate installed

Thank you all for your help. I'm addicted to this web site. Everyone is so knowledgeable and helpful. I did use a small sharp chisel to remove the breakaway bolt. That worked quite well. Once the breakaway bolt was out of the way, the rest of the installation was simple. I do have a question about the new torque plate. Should I notice a huge difference in performance. It seems that it's a little faster out of the hole and a little better on hills but it's not a day and night difference. I don't have any more smoke than I did before so I didn't adjust the star wheel. I have not tried pulling my 5th wheel yet. I may notice a difference there.



thanks,

James

 

[krs]

You should have a pretty awesome improvement. If there's any question you may have another adjustment to make which is described here:http://www.piersdiesel.com/TechLeverAdj.htm