Engine/Transmission (1994 - 1998) The damage is done (KDP), info/help needed

[Stranger]

In my post "How much is this gonna cost me?", I noted that the d***ed KDP did it's thing.



Here is where I'm at.

 

[Stranger]

How much more needs to come off?

 

[Scrappy]

OUCH!

That hurts! This is gonna hurt more, you gotta remove the cam to replace that housing:{ . that really sucks for ya'. I hope you get the better of it.

 

[Blakers]

Do some searches before you do anything. You don't have to remove the cam. Some do it and some don't.

 

[HVAC]

Don't Remove The Cam?

How do you get that gearcase off without removing the cam



I just purchased a gearcase for a "P" pump and it ran 205 from C West.



You will need to get the "P" pump loose from the gearcase, pull the cam, and then remove the power steering pump from the gearcase. Now your ready to remove the gearcase and fit a new one.



BTW, for anyone reading this, we have a KDP tool here in the bay area.

 

[PUMPERDUDE]

HVAC,I think Blakers is refering to only pulling the cam gear as Cummins does now.

 

[HVAC]

Cam Gear

Yeah, I suppose it could be done. But I tried like crazy and couldn't budge that gear. Guys I've talked to have told me it takes a good size hydraulic press to get that gear off. When reinstalling it you can heat the gear and cool the cam to ease the fit.



Anybody here ever remove the gear off the cam? Anybody do it while it's still installed in the engine?

 

[JWaters]

gear

We bought the kit from cummins and it didnt work, much quicker to just remove the cam, dont for get to take the fuel pump aloose.

 

[Stranger]

Thanks guys.

 

[illflem]

The gear can be removed while on the engine with a manual puller, my buddy at Cummins NW says that's the only way they do it nowadays.

Joe D had the best advice though -

The removing the gear method is the one you use when it isn't your truck, there are just too many things that can go wrong.



Every time I see pictures like strangers it makes me glad I used a jig

 

[Joseph Donnelly]

Remove valve covers, rockers, pushrods. Put 1/2" wooden dowel rods into each lifter (chamfer and split with a hack saw the end, drive in with a mallet so they hold securely), lift, and clothespin to hold the lifters up. Remove 2 bolts, cam retainer, camshaft with gear on it. Remove injection pump gear, pump, vacuum/ps pump from gear case. Replace gear case, putting timing pin housing on new case, aligned for TDC.



Not a job for the learner or faint at heart. Also you need a new dowel pin to help align the gear case. Cummins #3900257.



Use RTV sealer for gear case to oil pan. The new pink gear case to block gasket 3938156 goes on dry.

 

[eberga]

I just finished the fixing the kdp damage on my truck. I pulled the cam out to replace it. It wasnt too bad of a job for someone with some mechanical know how. Be sure to make a mark on your pump gear and the shaft to make sure you dont change the timing when putting the gear back on. It doesnt have a key, just a tapered shaft. Clean the shaft with brake cleaner and blow it dry with compressor. Also be sure to take the lift pump off before trying to pull the cam. The new case was $205 from cummins. With all new gaskets, case and crank seal I spent about $370 plus new oil and anti freeze.