I killed my third KDP tonight, fabricated a tab to hold it, along with LockTiteing all other bolts in the gear case and torqueing everything to spec, adjusting the valves, flushing the radiator, changing the valve cover gaskets and front main seal. Whoo, tired. Well, the 97 that I bought last week is almost ready mechanically. I had it inspected and it needs two lower ball joints. Getting those, front end alignment (toe only, as I understand?) and tires trued and balanced Monday. All I need now is a miracle paint job. I should have less than 16K in the truck when I am completely through.
Now, I know that seems like too much to some of you, but consider that this truck is immaculate inside, will have a new complete paint job, front end tight, and the previous owner just put a TST #8 plate, new gauges from Geno's (the Indiglo looking white faces with an A pillar pod mount, EGT and Boost), a new Magna Flow Dyno Max 4" exhaust, new tires and Eagle alloy wheels, a new Tekonsha Voyager brake controller, and many more extras I would normally have to add myself. Oh yea, it has a chrome brush guard still in the box and a deep tool box. I am pretty happy with it so far, the best part, it has only 71 K miles on it. ACTUAL Miles! I think we should be able to keep this one for a long time.
Oh yea, the KDP was on it's way out. It had moved about an 1/8-1/4 inch and the bolts in the gear case were a little too loose for comfort. Well gotta go to bed. Gotta work tomorrow.
Chris

 

Sounds like you've got it ready to just enjoy driving it. May I suggest getting a new overflow valve for prevantive maintenance as well? Always good to have one on the shelf, but they have a life of about 75k miles. The OF valve is probably the single item the wears out most often on a 12 valve.

Precision Diesel Injection and Turbo Inc.
Marty Tompkins
888-734-7349
$35 + $5 shipping and handling.
Replacement takes one wrench and five minutes.

 

You are ok on the price, I have a 97 that just turned 65k miles and I wouldn't take what you will have in yours for it. I have turned down 18k for it. These sec gen's with low miles are getting harder and harder to come across. Goodluck,,,Rick

 

What is the Overflow Valve? I am not familiar with this.
Thanks
Chris

 

It regulates fuel pressure seen by the injection pump.

Symptoms of a bad one is:
low RPM miss/instability
white smoke
hard starting
engine dies at idle
low power
fuel filter cracking

Dealers want about $160 for one but if you buy it ahead of time from Marty it'll only set ya back about $42, quite a few here carry an extra one just in case. Their service life is about 75k miles.