I fixed my KDP today using the tab method. Has anyone heard of the tab falling off because of the bolt backing out? I cleaned the bolt hole and used med strength thread loc(the blue stuff) and torque the bolt to 18 ft lbs. It looks like if the tab falls out it will cause as much or more damage than the KDP.:P

 

As you did, I always use loctite on the bolt, and I shape my KDP tab to fit the recess so it cannot rotate if the bolt somehow backs off. Lastly, I always retorque the rest of the gear housing bolts while I am in there. I can't see that bolt ever coming out with the loctite on it.

 

I'm not sure, but I think the dang thing has no function once the housing is bolted in, It is just a location pin used for assembly. So if someone took all the time and effort to dissassemble the front cover, why not just grab the darn thing and remove it? unless it is tight and you can't get to it?
You sound like you are right about the bolt and tab, they would do more damage then the pin.