Finally got up enough motivation to do the KDP fix (too windy to fish). Took a 12 pack and half a bottle of whiskey but I got er done and only have one extra bolt! Now I see why the kit recommends having someone help... you need a buddy to help drink the beer and find your tools after you loose your cool and throw them Happy to announce that the suspect dowel pin was in it's original position! Unfortunately the bolt right next to it was only finger tight as were the other three bolts inside the case! I about felt like vomiting when I discovered these... if it weren't for all the beer and whiskey. The serpentine belt was pretty mangled as well (not stock) from someone's shade tree attempt to change the water pump and belt some years ago. only about 2/3 of the width of the belt was still there.

If you haven't done the KDP fix yet, for GOD sakes why not!

Makes me sick to think that these motors were built and shipped out this way! If they were built by Mopar that never would have happened!

 

Don't want to rain on your parade, but there are 6 or 7 bolts inside the case, IIRC...Mark

 

Be sure to double check the belt's tensioner for normal aging.
It's rubber component will let the thing droop to the side thus allowing it to steer the belt wrong such that it rides off the pulleys. A belt that has been reduced to less than it's original width is a sign of impending doom (for the belt).

 

Yes you are raining on my parade. The instructions that came with the KDP fix kit shows only 3 inner case bolts. The sticky on this forum shows an error code so it was no help. Do you have a link (that works) showing pics of these other bolts?

 

Type in cummins dodge timing gear housing, At ebay theres one in paris arkansas got a nice pic youll see the bolt holes i counted 6

 

Here it is...Mark


http://www.flickr.com/photos/63170901@N03/6019454926/http://www.flickr.com/photos/63170901@N03/6019454926/ by http://www.flickr.com/people/63170901@N03/, on Flickr

 

There are 5. The sixth one is the hole for the dowel pin. CRAP! Guess I'll be doing it again!

 

Well glad you got you KDP done. But like you my case bolts were only finger tight as well. Sucks having to take things back apart again, but being able to sleep at night makes it worth it.

 

I think that the lower of the 3 in a row is one that is behind a gear and I did not take that 1 completely out. I was afraid of dropping it down into the case, so I just loosened it as much as I could, put some locktite in the threads with a toothpick and re-torqued it. If I were to do it again, I would use a strong magnet and that would be enough to get it out. The problem was that the hole in the gear was not exactly in front of the bolt, so that it had to be angled out a bit..Mark

 

My instructions that came with the kit I bought at Pure Diesel Power only show two bolts behind the cam gear acessible via the cutouts in the gear. One was easily acessible, one was awkward and I had to use a magnet to remove and replace but I never noticed a 3rd. I am, to put it delicately, not happy...

I corrected my first post. I checked my instruction sheet and it shows 4 case bolts to tighten (which I did). The inherent problem with the case bolts is they bolt an aluminum case to a steel block both of which have differing rates of expansion and contraction due to heat. Not sure if even locktite will hold forever. Almost should be a requirement to check them every time you change the serpentine belt or every 100k.

 

You rotate the engine until the bolts behind the cam gear are in the clear. I use a balancer bolt in the end of the crankshaft to rotate the engine when the timing cover is removed.

 

You are more than right the the 6th is the PD.

Although I think I see 3 more, Triangle top gear hole Total 8 bolts.

I could be wrong, Its been a long time since I did mine.

 

I also did those, as well as the 4 oil pump ones (I think) in the lower left (as you look at the frront of the motor).Basically, I did every bolt that I could find.... Mark

 

If it werent for the beer and the whiskey you might have seen the other bolts jk my pin was fine too, but most of the case bolts were loose...

 

You didn't notice any of these others loose did you? They shouldn't be affected by the same stresses as the housing bolts.

On the 91 W350 I had 12 years ago one of the bolts did me in. Luckily I was going down hill to town and heard a pop like one of my tires threw a bolt into the wheel well and I looked down and had zero oil pressure. I was running Mobil 1 5W40 and drove it 7 miles to the dealership with no damage to the engine. Still cost $2000 to fix though.