454 to Cummins

[choctawmel]

Originally Posted by GCinSC2

Mel,

Exactly why you should look into the drill fixture technique. Its all external, cover stays on.

Gary

That thread for 'drill fixture technique' was from 2001.
What I've read is this is only an issue with 1989-93 12 valve and 1998.5-02 24 valve engines. Correct me if I wrong.

[Keyair]

Mel, I read It was your engine year.
Obviously it was mine too.
My reading tells me it was a problem up into the early 2000s. I gather they changed the machining on the timing cover so the pin cannot escape.

[GCinSC2]

Originally Posted by choctawmel

That thread for 'drill fixture technique' was from 2001.
What I've read is this is only an issue with 1989-93 12 valve and 1998.5-02 24 valve engines. Correct me if I wrong.

Mel,

I plum forgot what year your engine is, I've slept alot since you brought it home. Might take some research to pin down the years but I bought a '97 with a broken case from KDP failure and helped a neighbor do a pre failure repair on a 24V like an 01 or maybe 02 he's moved. He made a tab for his and saved the case.

Research, decide and act or?

Gary

[Keyair]

http://www.cumminshub.com/killer-dowel-pin.html

[GCinSC2]

I just found a thread where I identified the neighbors truck that I helped tab, it was a 98. Also reviewed a thread on 24V engines, it happened on them also but old case was being phased out in favor of stepped bore case pin hole that prevents pin movement.

[Keyair]

Mel, I know this is gonna be a huge pain to do. If it helps, I’m planning to make a retainer for mine soon, and I’d be happy to make 2 as I have the cover off and on the bench.
Here is another great article on fixing it.
http://dieseldatabase.com/dodge-cumm...-dowel-repair/

[choctawmel]

Originally Posted by GCinSC2

Mel,

I plum forgot what year your engine is, I've slept alot since you brought it home. Might take some research to pin down the years but I bought a '97 with a broken case from KDP failure and helped a neighbor do a pre failure repair on a 24V like an 01 or maybe 02 he's moved. He made a tab for his and saved the case.

Research, decide and act or?

Gary

Mine is a 1996. I've read some more on this and found I should schedule a little KDP preventive maintenance. I see the price range from $3.99 to $150.
Another (maybe) needed change is the harmonic damper. It shluld be inspected ever 30,000 miles. Anyone have any thoughts on the 'fluidampr' damper? Dang! Is another $419 part!

[choctawmel]

Originally Posted by Keyair

Mel, I know this is gonna be a huge pain to do. If it helps, I’m planning to make a retainer for mine soon, and I’d be happy to make 2 as I have the cover off and on the bench.
Here is another great article on fixing it.
http://dieseldatabase.com/dodge-cumm...-dowel-repair/

I sure don't want to have to change the housing. No room for removing the front push rods or room to put the dowel in. The motor would have to come out and the head would have to come off first. And let me tell you, that head is HEAVY!!!!

[Keyair]

Yup, I think if you can find this elusive drill jig it’s the lessor of multiple other evils

[GCinSC2]

Originally Posted by choctawmel

I sure don't want to have to change the housing.

Mel,

Only need to remove the gear housing would be if the pin comes out and breaks the gear case or worse. Taking some action either drill jig or removing the gear case cover is a whole lot less grief. The truck I bought chunked about a 3" section of case and spewed black oil big time. To R&R the gear case you have to remove and I'm skipping the petty stuff, remove the P7100, camshaft and harmonic damper.

Gary

[choctawmel]

Well for all you end of worlder's out there I decided to pull the guts out and look at the 'KDP'.
Got to be a way to catch and reuse the antifreeze. I did manage to catch about 2 gallon of dirty fluid. The rest, that didn't get me, hit the floor. Thought I was going to have to cut the radiator hoses off.

Had to take a new picture of how the belt goes.

Pulled the gear cover off and the little ol' pin is right where it was suppose to be.

Made myself a little washer to keep that little ol' pin where it belongs. Put some thread lock on the bolt and torqued it back in.

Cleaned the grease off the cover, the old gasket, put a new crank seal and gasket. Put it all back together.
Don't know why the bolt holes don't line up on re assembly. As many times as I've had this apart would think it would fit???
Guess it's a good thing I did this, because I found that I hadn't tightened the 10 bolts that hold the grill on. Wouldn't be fun going down the highway and the grill falls off.
Friday the weather is going to be in the 40's... Will be time to got check out the new injectors.

[GCinSC2]

Mel,

That's great. Now the pin cannot work it's way out, trash the case and if this was a PITA imagine pulling the cam.

Pump comes off, IIRC all rockers come off, push rods come out and now the do ya feel lucky part. You buy 1/2 wood dowel rods, slit the end about 3/4" or so, slight bevel on the end, tap into the tappet where the push rod was, lift it up, secure it, repeat 11 move times. This "allows" you to pull that 3' long cam and gear out the front thumpa thumpa thumpa as you struggle holding the cam and hope against all hopes that one of your custom made tapper holding dowel rods doesn't drop a tappet. That becomes a whole new chapter.

Replace case, reinstall all them parts, oh yeah you have to learn how to pin the pump to maintain timing before removal. Walk the cam back in, adjust valves and button all of that stuff back on.

Piece of cake. Like a wedding cake for 200 guests and you have to eat it all with chop sticks.

That's the crap shoot that this KDP represents.

You can rest easy now, good job.

Gary

[Keyair]

Nice job Mel!

[choctawmel]

Originally Posted by GCinSC2

Mel,

That's great. Now the pin cannot work it's way out, trash the case and if this was a PITA imagine pulling the cam.

Pump comes off, IIRC all rockers come off, push rods come out and now the do ya feel lucky part. You buy 1/2 wood dowel rods, slit the end about 3/4" or so, slight bevel on the end, tap into the tappet where the push rod was, lift it up, secure it, repeat 11 move times. This "allows" you to pull that 3' long cam and gear out the front thumpa thumpa thumpa as you struggle holding the cam and hope against all hopes that one of your custom made tapper holding dowel rods doesn't drop a tappet. That becomes a whole new chapter.

Replace case, reinstall all them parts, oh yeah you have to learn how to pin the pump to maintain timing before removal. Walk the cam back in, adjust valves and button all of that stuff back on.

Piece of cake. Like a wedding cake for 200 guests and you have to eat it all with chop sticks.

That's the crap shoot that this KDP represents.

You can rest easy now, good job.

Gary

Yes, I read a couple threads on my Cummins form and decided to check because can't pull the push rods. Now I hope my little fix don't fall out before it's time

BTY just remembered I wanted to replace the oil pump while I was in it..... Oh well maybe next time.
I got to do some more hands and knee work and adjust the P7100 'starwheel'. And it hurts really bad to get on my knees now.

As I await word on knee replacement. I can tell you that the VA health system sucks for getting anything done in a timely matter. Three months out for an 'in house' VA ortho appointment. Three weeks to get approval for one appointment out of system(was seen the next day by non VA). Now another 3 weeks or more to get approval for treatment. Oh and the VA denied paying anything for my overnight hospital stay when I had a stroke in May..... 'Non-emergent'... 'Authorization is required in advance'. I know, I need to plan better. Sorry about this... Just venting in pain.

[GCinSC2]

Originally Posted by choctawmel

Yes, I read a couple threads on my Cummins form and decided to check because can't pull the push rods. Now I hope my little fix don't fall out before it's time.

Nope you literally have it covered. It's staying put.

Good luck with the VA and knee issues.

[Smartstream]

Sorry to hear about your problems with the VA. I had both knees replaced recently and it's great for walking but kneeling is no fun. I found some gel filled knee pads at Lowes and they really make a big difference. Gook luck and a speedy recovery.

[Isuzusweet]

Originally Posted by Smartstream

Gook luck and a speedy recovery.

Is that what one Vietnam vet says to another Vietnam vet?🤔

[Smartstream]

I served during the Viet Nam era however I spent my time in Korea. The post however is what one guy with bad knees says to another guy with bad knees.

[choctawmel]

Originally Posted by Smartstream

Sorry to hear about your problems with the VA. I had both knees replaced recently and it's great for walking but kneeling is no fun. I found some gel filled knee pads at Lowes and they really make a big difference. Gook luck and a speedy recovery.

Thanks for the new on your knees. I'm hopeful the VA well go ahead and approve the (non-VA) treatment. Coming up on 2 weeks since the request was made. Trying to cancel and maybe get some of my money back for a trip to Iceland I made the week before I killed the knee. Sitting in an airplane for 14 hours would not be fun right now and it I got it replaced today I woundn't be able to by the trip date of 2Feb18.

[choctawmel]

Took Silver Bullet for a run yesterday. First off the bat the transmission was in 3rd gear limp mod. Went around the section and back to the barn. Wife said, "You're going to spend your last dime on this thing!" I smiled and said, "No better way to spent it." I put the shifter in neutral and crawled under and checked the shift actuator to the lever, pulled the carter pin, turned it half a turn, put the carter pin back in and went for the 100 miles ride.
Now let me brag: IT RAN GREAT!!!!!!! Biggest hill I went up it held 71mph on cruise. I'd loss mph going up that hill with the 454!!!! EGT went to 1225 degrees. I accelerates better than the 454. When I turned around the ramp and hill after did get the EGT up over 1300 degrees.... Not good:<(
I do have some smoke so I turned the starwheel too far and need to back down some. May put he stock fuel cam plate back in.
New injectors did make a BIG difference.