OK, i nocited a new sound coming from one of my trucks. sortof like holding a piece of metal up to a spinning brake rotor. everything works great still. the truck runs fine. i checked to see if the sound got louder when i took off the oil fill cap and unfortunately it did. there is also a decent amount of oil around the front part of the motor, though i have not taken the time to find the leak. i just took the truck 1300miles. and didn't notice the sound till i was about 300-500 miles from the end of my trip. so the oil leak could be small but had many miles to leak some out. i kept a watchful eye on the oil pressure and all is well there. someone please help me out with what i need to do next. i would guess it involves removing the front cover? thanks in advance
mark

 

Could be the KDP if it is not pinned. If it is you are one of the lucky few who can fix it with a new housing instead of a busted cam or worse.

 

so i need to pull the case and inspect the damage? what's a new housing run? and ideas?

 

Pull the fan mount and see if you can see a crack in the housing, that is where it will show up. I would go ahead and pull the cover and pin the KDP and tighten/locktite all the bolts while you are at it for safety. You may be lucky and it is only a bolt backed out and rubbing a gear? I don't know about cost but someone who has went that route will chime in here I am sure. Keep a watch on ebay though because i have seen them on there.

 

I'm not sure taking the oil fill cap off is a good indication. Its loud in there to begin with and taking the cap off only lets the noise get out easier.

 

but wouldn't that at least tell me that is where the sound is coming from?

 

ok so i took a flashlight out there and found where the problem is! looking at the motor almost center behind the fan there is what looks like a small eyedrop shaped tab held on by one bolt (engine still fully assembled) well on this truck that tab is gone and the housing around it is cracked. the reason i ask about the price of the housing is that there is a 1st gen motor at the local salvage yard. it is intercooled while mine is not. he wants $850 without inj pump and without turbo (kicking myself, was gonna get the whole truck for $1000 2 weeks ago) i would like the 7mm head for my truck, and if i can use the case on this one blah blah blah... anyone think this might be the way to go? thanks for continued input i will try to get pictures up in a few minutes

 

Is that one of them KDP tap fixes? The outside the case drill and tap? If so, looks like the cover is missing, obviously. Looks like you only need to fab a cover for that hole.

It is normal to hear all weird sounds with the oil fill cap removed.

 

from my 91 that is hurting.....



from my 91 that is NOT hurting.....

 

bgilbert, the case around that hole is cracked if you cannot see it. unless the upper part of the hole is supposed to wiggle when the cap is off?

 

Mark, I don't remember ever seeing a cover plate like that on any truck I've worked on - but I haven't worked on many non-intercooleds.

It sure looks to me like the KDP or one of the case bolts has worked loose and dropped in the gears.

 

dave, i looked at the intercooled motor at the salvage yard and there was not such cover plate. i'm sure my wife's truck looks the same. it looks like somewhere that you would insert a tool to turn the motor. the piece that is broken on the case pivot on the bolt that is holding it. if i remove the case cover and other things in the way, would it be possible to repair this part? my first though was jb weld or something like that. the broken part is aluminum and the brake seem to be clean from what i can see. i will try to get it apart and take some better picture tomorrow. if it is not repairable what does the new case cost? and what has to be removed to replace it? thanks guys!

 

It could be TIG welded. I think a new case is in the $400 range. Everything that's bolted to the case (IP, vac. pump, etc.) comes off, and you have to either pull the cam or the cam gear. If you pull the cam gear, you need to be able to heat it up to 450 degrees or so to get it back on.

 

I just looked at my 89, NON IC, and i dont have a hole or plate there.
Peter.

 

I bought a new cover from Cummins last year for $400, same price as the oil pan.
Man, I had better get busy! That picture looks scary.
I haven't killed my KDP yet.