Engine/Transmission (1994 - 1998) Tappet Cover R&R Details

[Man_of_Constant_Sorrow]

While the IP is out being rebuilt on my '95, I thought I'd follow the advice from this and other forums to replace the tappet cover gasket. I haven't found a step-by-step, and haven't found the section, if it exists, in the FSM. So as I look at it, it seems like the following parts have to be removed, am I correct? (I'm starting with the IP already removed, and the fuel filter off.)

IP mounting bracket from block. Looks like the top plate of it can be removed, scribing a match mark so I can put it back on at the same angle.
IP oil supply tube from block. Any seals involved with this?
Breather tube
Fuel supply tube from (stock) lift pump to filter head -- or maybe detach filter head and fuel pump from block leaving them connected to one another, but then I'd need a fuel pump to block gasket. It looks like there might not be enough clearance if the lift pump is left in place though.

Thanks for any input.

 

[Man_of_Constant_Sorrow]

Hmm, well, I got into this tonight. I found that I did not need to remove the fuel lift pump, but did have to remove the aforementioned IP bracket, IP oil supply tube (no apparent seal involved), breather tube, and both hardlines going to the lift pump. I broke the noise cover trying to remove it first; my guess is that if I'd taken the hardlines out of the way first, the tappet cover with noise cover attached would have come out as an assembly.
The gasket was not leaking, not cracked, probably would have been fine for awhile, but the rubber is hard and dry after 23 years. Easier to do it now than later.
Now I just need to figure out how to clean the rusty, gummy gasket mounting surface on the block without getting a lot of debris all over the tappets and into the engine!

 

[Timd32]

Have you registered your ESN in Quickserve it's free?

They have a lot of detail on most of these parts.

https://quickserve.cummins.com

Mine showed up under Lubrication > Engine > Cam Follower Cover

Sometime you have to dig a bit, for those of us that this is just a hobby and not out everyday job.

 

[BigPapa]

Good info here:

https://www.turbodieselregister.com/threads/235791-Replacing-tappet-cover-gasket-hints

 

[Man_of_Constant_Sorrow]

Thanks, @TimD32, I did find some info under the service tab on that site, the most important nugget being the torque spec on the cover bolts is 18 ft-lbs. They seemed looser than that when I removed them.
@BigPapa, I appreciate that link -- I have seen others like it, but I seem to learn a lot whenever @GAmes is involved in a thread! I'm going to take my time with this tricky gasket, and I'll check for gaps like he did. The ergonomics of working on the left side of this engine, especially around cylinders 5 & 6, leaves much to be desired.
The rear stud for the noise panel broke off, and the part of the noise panel that goes around the breather is broken off from the rest. Do I glue this to the tappet cover, or if I leave it off, how much louder is it likely to make the engine?

 

[BigPapa]

I left mine off. Didn't notice much difference. They all get hard and break off at one time or another.

 

[GAmes]

I tossed mine long ago.

 

[Man_of_Constant_Sorrow]

Ok, let's talk grommet seals. There are six bolts with grommets holding the tappet cover on. So I look these up over at Cummins QuickServe, under Lubrication System - Engine - Cam Follower Cover. There are two entries. Looking at the first one, it shows that the cover requires four (not six) of part number 3900267. The second entry shows that two of part 3928759 are required on the cover bolts on both sides of the breather. I thought, ok, somehow those two are different. When I removed them from the old cover, I couldn't see any difference. And when I got the parts, the two by the breather are nothing like the other four, nor like what was there. Is the quickserve wrong, or were the wrong things on the truck?
At Geno's they say you need six of the first kind, 3900267, and that the other kind is for 98.5-02 trucks. See https://www.genosgarage.com/product/dodge-ram-cummins-tappet-cover-bolt-grommet-seal-3900267/gaskets-and-seals for first one, and https://www.genosgarage.com/product/dodge-ram-cummins-tappet-cover-bolt-grommet-seal-3928759/gaskets-and-seals for the second.
This, and finding some of that famous 3M yellow sealant are holding me up now.

 

[BigPapa]

I looked up my '95 on QuickServe and you are correct, it calls for (4) 3900267 Grommet Seal and (2) 3928759 Grommet Seals on each side of the breather. However, the Lower Gasket Set, 3802376-01, contains (8) 3928759's and no 3900267's. Maybe Mike, mwilson, will chime in here with his opinion.

The 3M Weather Strip Adhesive should be readily available at any parts store,
O'Reilly's, Autozone, Advance, etc.

 

[Bromiley99]

One quick tip you might already know but that gasket is directional, the little tab goes towards the front of the engine, an the words or arrow face you as the cover bolts up. If you don't get it on right oil will RUN out the side of your motor. I would say quickserve is wrong, I've never seen a mix match of the two grommets on a truck, go with (6) 3900267 I'm assuming that's that was there.

 

[Man_of_Constant_Sorrow]

I saw 3M black weatherstrip adhesive, regular and extra strength, but not the famous yellow formula. Would Permatex black be acceptable? I am probably going to use some on the two grommets that I'll have to reuse due to getting the wrong parts above. At least if they leak, it won't require removal of the IP to replace them. Yep, Bromiley, I know about the tab direction -- this is an unforgiving gasket by all accounts.

 

[GAmes]

I used ultra gray with good results.

 

[southernman]

Guys I just went through the valve tappet cover gasket replacement and what a disaster.

Started with a new "blue" gasket as recommended in the NAPA parts site. It blew out within 1 week of being installed. Service manual says no adhesive, and that's how it was installed.

After chasing down numerous sources, I finally was able to reach Jim Jessup, of Jessup Diesel, who worked for Cummins for over 33 years; was instrumental in creating our Service Manuals; and also runs one of the most respected Cummins Training centers in the country. I was shocked I actually got Jim, but he happened to be in during lunch when no one else could get to the phone. Hi guy Layton runs day-to-day operations now and they're booked out about 6-8 weeks depending on the work you want done. Great bunch of guys.

Jim explained the failures: Many years ago, some lunk headed bean-counter decided, based on a visual comparison, that the Gen2 and Gen3 gaskets "looked" so much alike, that they would value engineer the Gen2 gaskets, and just sell the Gen3 gasket to service both engines. Big mistake, since a very close inspection will reveal differences in thickness in critical areas, and explains why the blue gasket doesn't work (without aggressive sealant to fill the void) on the Gen2's, which require a black gasket..luckily, the gaskets are different colors and they didn't change both to black or blue. Blue = Gen3 and Black = Gen2. They do not (properly) interchange and per Jim, it's not a question of "if" should you use the blues on a Gen2...

Per Jim, the black gasket part number (and the one I purchased and installed) was PS38801, which is a Victor Rienz (Made for them by Mahle) part number, and comes with the grommets as well. It went is tight against the tappet cover, requiring no sealant, and it's been working perfect ever since.

Also, Jim's shop charges 2 hours labor for replacing this gasket. The reason why ? Because immediately after Dodge value engineered the black gasket, Jim's shop was flooded with repairs previously made using the blue Gen 3 gaskets in Gen2 trucks, and after fixing hundreds (if not thousands) of these trucks, they've got it down to a science. Jim stated he's had vehicles towed from nearly every state in the country, as many shops were unable to stop, or figure out, why they were seeing failures. Per Jim; if anyone doubts that claim, tell 'em load their truck up and bring it in and we'll fix it in 2 hours, and their bill will reflect it too..

Again, just a heads up and hopefully enough Gen2 guys get his information before having to do it over - as I did.

Southernman