I fixed the KDP on my higher mileage 95 today ;D. Not a 2 hour job. But that was mostly because of the crank seal giving me such a hard time. Really busted my chops trying to get it on. I finally took some 400 grit wet paper and polished the end of the crank, then it slipped right on. My pin was protruding approximately 5/16&quot;. I tapped it back in and fabricated a block out of 16 gauge stainless. Retorqued all the bolts inside the case, non were real loose.<br><br>I still have to do my 4x4, I'll try and get it next Saturday. For those getting ready to tackle this, here is what I suggest, or at least what worked for me.<br><br>--Pull the Passenger side battery cable off and set aside.<br>--Also, disconnect the driver side, positive cable. I have a bad habit of using my batteries for tool tray, so I always disconnect them and cover the positive terminals.<br>--Drain a gallon of anti freeze off and remove the top hose.<br>--Take the washer resevoir bottle out.<br>--Pull the radiator shroud out.<br>--Fan presented a small challenge. It is right hand thread, and it wants to slip on the belt. Also, I don't have a 1 7/16&quot; open end wrench, but I do have a big A## crescent wrench. But it is to fat to grasp the nut, &amp; cleat the pulley and fan.So, I took one of the four bolts out of the fan and two bolts out of the pulley. Now the wrench will fit. To solve the slippage I took a VERY large pair of Channel locks, grab the pulley and with the crescent wrench the nut broke free very easily. Remember turn it clockwise to loosen. Set the fan assembly aside.<br>--Now loosen the bolts on the pulley, but don't remove them. Just lossen them slightly. You have to take the belt off before you take the pulley off and loosening them with the belt on makes it easier.<br>--Now take the belt off. 3/8 drive ratchet in the idler will give you the slack. Be careful. There is A LOT of torque on the idler.<br>--Now take the pulley off.<br>--Next take the pulley housing off.<br>--The tac sensor is next. First get a feeler gauge and figure out the gap between the probe and the harmonic balancer. Once you have that, set the feeler gauge aside. Now go ahead and remove the tac sensor.<br>--Now take the four bolts out of the Harmonic balancer. You'll need a long 1/2 inch ratchet and by using the engines compression and some good pops with the wrench they will all break loose. The the unit pulls right off.<br>--Now blow any loose dirt and oil off the cover.<br>--Remove the 20 bolts off the cover. You'll need to pay some attention to how they are placed. Several must be put back in specific locations.<br>--Gently remove the cover. If it does not literally fall off, you have probably missed a bolt. DO NOT PRY IT OFF!!<br>--Find the dowel and if necessary tap it back in. If not necessary, consider yourself lucky. <br>--Make your KDP cover &amp; bolt it in.<br>--Check all the torques inside the case.<br>--Put the cover on.<br>--I was able to re-use all the seals., Just clean the cover seal and put some silicone on both surfaces.<br>--Reverse this procedure and your done. ;D ;D ;D<br><br>Or, you can buy a kit to drill a hole, tap it out and put in a blocking bolt. Problem, as I see it, is the is no way to tell if your dowel has migrated out or not. SO, you may as well pull the cover and save yourself $300 bucks.<br>--PM me if you need more info.<br><br>Good luck, Gary<br><br>

 

Glad to see another member will be able to sleep at night ;D and not worry if the next time he starts his truck will it launch a dowel pin thru the gear case

I have the KDP Jig kit and after the first one it only takes an hour to do a fix as long as the dowel hasnt moved out very far until I fixed my dowel I always worryed about it happening 2000 miles from home and needing to fix it in some small town while I waited in a motel room :-[


Iam thinking of starting a KDP Jig Kit Shipping to member of this forum if your interested send me a E-Mail to find out the details pappy@phantomcycle.com

 

Drifter is correct. Just went down and miced the gauge I used and .50 it is.

 

.50 or .050? I don't have any feeler guages as big as .50...<br><br>

 

.050

 

Actually, if you get a gap setting prior to removing the sensor, then you can just use that while reinstalling it.

 

Hey WOODRAT, if you don't have a .050 feeler gauge. Fear not. Just take 3 or 4 and add the numbers up till your at .050.