The key for the injector pump fell into the motor- what should I do now?

[GTX_Joel]

I took the injector pump off to replace the leaky O ring on the back side. When I was putting the pump back on, the key fell out of the keyway and went down in the motor where I can't see it. :{

What should I do now? I hope I don't have to take off the whole front cover.



Thanks, Joel

 

[John - K5AWO]

I would get one of those extensionable magnets from the auto parts store. The ones that will lift 5 lb loads. Use it to search the top of the cam gears. If it fell clear and went to the bottom, you are okay. However, if it is on top of the gears or between the cam gear and the case... you got big troubles.



Myself, I would be awful nervous about trying to start the engine. The next noise you hear just might be broken case parts or gears, or worse a busted cam shaft.



There are several KDP threads with pictures of the carnage resulting from the KDP dowel pin falling about. That keyway slot is just as hard as the KDP pin.



If that magnet doesn't retrieve the key, I would pull the front cover and find it.



Get a small mechanics mirror, a bright light and go searching before you put the magnet down inside. Maybe with luck you can see it.

 

[jwilmoth]

If you can't get it with a magnet, its pretty simple to pull front gear case cover ( I have mine off right now for new gasket and some pump work) You'll have to pull fan and crankshaft pulley not a big job You will need new gasket and crank seal kit ($47. 00 at Cummins NW) This would be a good time for a new gasket anyway.

Good luck

 

[Bob Beauchaine]

Joel - if you do pull the front cover be sure to address the 5 10mm bolts inside that cover that hold the case on to the front of the engine. If they come loose - and they have been know to - they can do as much damage as the dowel pin or the key. I did mine this spring and found they were secure but not any where near as tight as I would like. Four of them can be removed cleaned, loctited and reinstalled, the other one is behind the P/S & Vacuum pump drive gear. You can bend a 10mm wrench about 45 degrees and loosen it enough to clean it and loctite it.



Good luck

 

[GTX_Joel]

Thanks for all the replys, this place is great!



Went fishing, got skunked, covers coming off. I'm going to pull the radiator to make it easier tp get at stuff and then I can have the radiator boiled out while I'm at it.



Thanks again, Joel

 

[1stgen4evr]

Key fell off

When you get back to where you were installing the pump, put a very small ding on the side of the key with a center punch where it fits in the slot. That should secure it so you won't have a repeat. While you are inside, you will no doubt do the KDP. Cleaning the radiator is a good idea as well. Some times these trucks can be lots of fun. Especially with Murphys help.



Better luck fishing next time. I don't know how to fish so I don't even go.



James

 

[GTX_Joel]

New problem

Well, I found it! It was on a little ledge next to the cam gear. Definetely could have done some damage.



Now my new problem. I busted the timing pin off in the cam gear. I left the pin engaged, then when I was taking off the damper bolts, the motor turned and SNAP, no more timing pin. Oops.



So where can I get a new timing pin and gasket and seal kit tommorrow?

Thanks, Joel

 

[KLockliear]

The replacement timing pin isn't the problem. How to get the tip that broke off out of the cam gear hole is the PITA.

 

[sbentz]

Keith is right. Tricky. Sometimes you can take a fine thread screw, heat it up, and melt it into the stub in the gear. Wait for it to cool. CAREFully pull it out. Otherwise, drill and blast.

 

[GTX_Joel]

Luckily the tip of the pin is not in the cam gear. It must have fallen out and into the pan because I can't find it. It's plastic so I'm not too worried about it. Hopefully it will come out with the oil.

 

[dpuckett]

Glad I aint the only one to have lost the key. I lost it on one one time, and took the cover off, tabbed the KDP, and then got the pump gear a tooth off upon reinstall. LOTS of white smoke, wouldnt harly idle. Had to take the pump off, move the gear back to where it was, and put it all back together. Fortunately, you can move the gear without taking the front cover back off. Never did find the key, though. Maybe it fell into the grass (it came off as I was removing the pump) or it fell into the oil pan and stayed there. Put 10K more miles on it with no trouble. I have broken a timing pin or two in my time, too. No big deal, the old pin can hold the oil in there, just have to use your finger at the next overhead adjustment. Or go spend $12 at CaseIH for a new one.



Daniel

 

[BushWakr - RIP]

"..... CAREFully pull it out. Otherwise, drill and blast.



:-laf :-laf...



Man that fits right in here with these guys... good one Scott...



Pb.

 

[GTX_Joel]

Mission accomplished!

Well, the old Cummins is rattling happily along with no more fuel leaks, a nice clean cooling system and freshly adjusted valve lash.



Thanks for the help!

Joel