I am tackling the KDP this afternoon. Am following instructions that I found on this website. So far so good. Got the fan nut loose. Removed 6 bolts on the fan bracket, then removed four bolts. Now it says to remove the bolts that hold the gear cover on. Cant get at some of them cause the fan mount is still there. How does it come off? Beat on it with a hammer? Also, where is the vibration damper. I dont mind asking questions when Im stumped. Can usually fix anything one way or another but HELP!! I know its probably so easy Im making it hard.

 

Haven't seen the KDP fix here yet, but if it were me I would go to the auto parts store and get a book on your vehicle so you can at least identify the parts that need to be removed to make repairs. They usually have very good illustrations and step by step instructions. Also big hammer = broken parts or hole in radiator

 

the vibration dampner is the biggest pulley toward the bottom of the engine also make sure you put the dampner sensor back to its correct setting it is located right above the dampner pulley. i always remove the whole fan asembly but i know it can be done with just removing the fan someone will chime in soon and tell you how to do it without removing the fan assembly

 

I have done several of these in the last year. If you have your fan out, I assume you have your shroud out, the belt off and the top radiator hose off. The fan bracket has four 10 mm bolts attaching it to the block. I just take these bolts out, the top three can come all the way out, the bottom right has to be done last and worked out with an open end wrench. There is not enough clearance to pull the bolt out with the fan and pulley still in place. It creates a large assembly that has to be managed out with the shroud, but I have done it both ways and prefer this way.
The dampener, or called the Harmonic Balancer on gas engines, is on the crankshaft, it has 4- 15mm bolts holding it in. Take the 15mm bolts out, you will probably have to hold the balancer with something (maybe wedge a screwdriver in between the fram and one of the slots) to get the bolts to break loose. The dampener just pulls off then, no need for a puller, just rock it off with your hand.

You can then take out all of the cover bolts BUT, before taking out the bolts, lay your gasket on the cardboard and trace it out, marking the holes, and orienting the cardboard with your mounted cover. This way, you can put the bolts in their corresponding holes in the cardboard so that when it comes time to put it back together, there is no question about where this long bolt goes and that short bolt goes. They are different lengths. While you are in there, go ahead and lock tite and torque (very important to torque at 18 ft lbs.) all of the bolts in the gear case. I do them one at a time. Some are 13mm and others 10mm. Tap the KDP back in lightly and put lock tite on it, then fabricate a plate to cover it, using the bolt next to it.
You will need to replace the front main seal and clean the crank output shaft while you have the cover off. The instructions for it are confusing. I knock the old one out with a punch and then put locktite on the edge and drive it in with the metal tool hitting it at 6/12 and 3/9 oclock. It take a little while and needs to be sunk to the depth of the tool. DO NOT! knock out the plastic sleeve. This is what keeps the seal in position over the crank when the cover goes on. Once the cover and everything is clean, I always put a thin layer of Form A Gasket 2 on the surface to be mated, then the gasket and put the cover back on. It will take a very delicate touch to get it on without messing up the seal. Good luck.
Just reinstall everything you took off. Torque the cover bolts to 18ft lbs and the dampener bolts to 90. (My service books conflict on that, one says 135,ouch, the other says 90) I think 90 is enough.
If you took the fan assembly out, make sure you put the shroud and the fan back in at the same time. You will have to hole the assembly up and work the bottom right bolt in to get it started and wrench that one in before the others.
I hope this long explanation will help, if you have any questions, just ask. I have done the valves and the KDP on these four times now, and I usually learn a lot every time.
Chris

 

Thank you eng208. Very helpful info. I overlooked that last bolt on the fan bracket and couldnt figure why it would not come off. There is nothing easy to get to on these Beasts but its fun trying. Thanks again

 

Glad I could help. I don't know what I would do without this information board. It sure does save a lot of money, being able to work on stuff myself and know what is going on.
Chris

 

Make sure the crank seal surface is clean, dry, and smooth. Use brake clean on it just before reassembly. No oil or sealant should be on the seal surface of the crankshaft. Bone dry. Kevin

 

Thanks guys, I will prevail.