Engine/Transmission (1998.5 - 2002) Pump gear thread size?

[NScott]

I had the VP44 go out on my 99 3500 after only 45,000 miles and am doing the replacement myself along with some injector upgrades. (its a perfect time since the air horn, injector lines and other parts are off now)

My problem and question seem to be that when I am trying to thread the two small bolts into the pump gear in order to pull the gear, I can only get them in at the most about 3 threads. I checked the threads with a mirror and they seem to be OK and go all the way through the gear. I checked the thread size of the bolts and they are M8X1. 25 which I believe are also correct.

I was afraid to tighten the bolts in the gear any more because I thought they will twist off in the gear and cause a small repair(pump replacement) to turn into a large repair(taking the core support and all related parts off to remove the timing cover)

What does anyone think is wrong here? Is thread size correct at M8X1. 25?

Should I take a thread tap and chase the threads in the gear? I dont want to get shavings into the engine if I do this and I don't really know what is up with the threads on my pump gear. Help please.

 

[FLynes]

Do a search for DieselDan and his putfiles on the VP44 repair... it will walk you through and is a Godsend.



I don't have access to it on my work computer (I work till 2300), so I can't remember off the top of my head what the values are.

 

[NScott]

I watched the Diesel Dan's Videos over and over and he shows the

Snap On #SP504 puller SP504, Puller, Gear He is shown using it and threading the puller bolts into the pump gear by hand. He seems to have no problems running them up with his fingers. On my pump gear this is impossible, I could just barely get them into the gear three turns using a wrench. I really don't understand what can be the problem. Any ideas?

 

[AlaskanCummins]

If memory serves me right, I got mine started with a couple of threads and then had to use an open end wrench to get another 3-5 turns into the gear. I thought too at first that it was a bit difficult and that I might strip the threads out, but as long as you get them started, you should be fine. It does seem odd though that you can't get more than 3 turns into it.



I used an old steering wheel puller that I modified (shortened the center bolt as it wouldn't fit - too long and got into the radiator). I was too cheap to buy that nice tool that Diesel Dan uses. It didn't take many turns of the wrench on the center bolt to get the gear to pop loose.



What I was freaked out the most was making sure I had the keyway in the 12 o'clock position - I must have checked 2 dozen times! :-laf