Engine/Transmission (1998.5 - 2002) VP44 Shaft Key Fell down in Timing Case

[SConklin]

I posted this in the 911 section as well...



I was trying to install and line up the new VP44, and the little key on the pump's shaft fell down into the timing case. I've pulled as much of the cover off now as I can without removing the water pump, and pried it back. Also removed the pump shaft gear.

I still cannot see the key down in the gears or the case. I have the key from the old pump still, and was wondering that, if the key is not in sight, would it have gone anywhere that I can leave it and use the other one? Or, will I need to pull more stuff off and find it for sure? Could it have gone behind the gears? How about down in the oil pan?

Also, now that the gear for the pump shaft is off, how do I make sure that the gear is lined up right (The keyway was not exactly at TDC before - it was close, but I'm not exactly sure where it was at before being removed. Or does it matter?

Any other ideas/help? This is my only vehicle, and it's currently out of commission because of this, so any help would be really appreciated.

Thanks!



Skyler

 

[dlange]

I know how you feel. When installing mine I had everything but the nut and lock washer on, and the washer fell into the case. I could not reach it either. I had to loosen all the bolts on the cover from the top down. I did not take them all out though. I reached in with a magnet and fished it out. Since the washer is larger I had no choice, but I would still get the key out. I beleive the key is mached to the pump. Stay with it buddy and you'll make it!!



P. S I put mine back together without a new seal, and no leaks.



Good Luck-Dave

 

[stacerbob]

The key is matched to the replacement pump. You can check the numbers on both pumps and see if they are the same (slim to none chance) But I still would want it out for sure.

 

[SConklin]

Update: Found the key, but haven't got it out yet. It's behind one of the gears, still working on getting it. Problem now is, the pump shaft gear is out, and we're not 100% sure how to get it alligned/timed right so that it's back in correctly. Anyone know how to do this? We're doing this without a shop manual (getting one asap now, but it's easter sunday, so we can't now till monday. ) So, TDR is our only source of help for now. The gears have marks on them, but we're not 100% sure of how they're supposed to line back up.



Skyler

 

[A Johnson]

Turn your crank until the key way in the crank is @ 12oclock, the crank should have an 0 and the cam should have a 00, the crank0 should be between the cam00 (like two eyes and a mouth) if they are not like this turn the crankshaft 1 revolution and they should line up. You will then see the timing marks between the cam and the pump gear and it should be pretty obvious how they go. Also when all the gears are in this position, the pump gear TDC scribe will be at the 12 O clock position. Once you get all the marks lined up and the pump gear back in, turn the engine until the key way is at the 12 O clock position so the next pump key doesn't fall out again. Also look at the pump key it will have an arrow on it, this needs to point towards the fuel pump. Good luck,



A Johnson



On Edit: Go here, http://free-quickserve.cummins.com/ and you can log in as a new user and if you have a Cummins serial # off your engine, it should let you in to look at manuals and such.

 

[Bob Wagner]

Andy, Thank you for the link

 

[SConklin]

Thanks for the info.



Finally got time to finish getting the key out and timing the gear. Disconnected the FASS and bumped the starter a few times to turn the crank and get the gears lined up right and turned completely around 180 degrees (the double-0's were all together). Once we turned everything, all the gears matched up perfectly.



Now it's time to put everything back together. At least that's the downhill part! (Even if it's tons of parts all over the garage. )



Skyler