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KDP (Killer Dowel Pin) Dodge Cummins 5.9L Engine Repair Kit

December 6th, 2010 · No Comments

Installation 1040182-3 KDP (Killer Dowel Pin) Repair Kit
1. Remove the fan drive assembly.
2. Remove the fan belt and the belt tensioner.
3. Remove the oil fill tube and adapter (12V only).
4. Remove the vibration damper.
5. Remove the bolts that hold the gear cover to the gear housing.
6. Gently pry the cover away from the housing, taking care not to mar the gasket surfaces.
7. Clean the old gasket residue from the back of the gear cover and front of the gear housing.
Installation
1. Knock the KDP back into place and install the Tab under the adjacent bolt.
2. Lubricate the front gear train with clean engine oil.
3. Thoroughly clean the front seal area of the crankshaft. The seal lip and the sealing surface on the crankshaft must be free from any oil residue to prevent seal leaks.
4. Install the seal into the rear of the cover using a plastic hammer and the alignment/installation tool provided in the seal kit to prevent damage to the seal carrier. Hit the alignment/installation tool alternately at the 12, 3, 6 and 9 o’clock positions.
5. Install the pilot from the seal kit onto the crankshaft.
6. Using the pilot as an alignment tool, install the cover and a new gasket (12v) or use sealant (24v).
7. Install the cover bolts and tighten to 24 N·m (18 lbs-ft) of torque. Remove pilot tool.
8. Install the oil fill tube and mounting bolts. Tighten the bolts to 43 N·m (32 lbs-ft) of torque.
9. Install the vibration damper. DO NOT torque the bolts at this time.
10. Install the belt tensioner. Tighten the mounting bolts to 43 N·m (32 lbs-ft) of torque.
11. Raise the belt tensioner to install the belt.
12. Tighten the vibration damper bolts to 125 N·m (92 lbs-ft) of torque. Use an engine barring tool to keep the engine from rotating during tightening operation.
13. Install the fan drive assembly.

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