Ok, dumb question but here goes. When did they fix the KDP? I thought they did but want to be sure. I thought they fixed the 5th gear problem on my truck untill I lost 5th gear 2 days ago. Thanks

Eric

 

The newest engine that I've seen the kdp problem on is '99.
Cummins says they fixed it in '98 but apparently some of the non-revised gear cases made it into '99.

 

The KDP problem is still with some 2002 model trucks. It is dependent on where the engine was assembled, so it is a good idea to take a look at some time. Cummins supposedly used a better bolt torque plan after 1999 to keep the aluminum housing from working loose and pulling the pin, but anything with some miles is now at risk. The new housings have a constricted area so the pin does not go all the way through, but sets in the hole deeper and leaves part of the hole open when you look into it. Pull your metal cover off the front and you will be able to tell in a minute if yours has the new housing.

On your fifth gear, do not go to Dodge for a fix. Go to Six States or one of the aftermarket transmission parts places that will provide you with the revised shaft that has the full length spline. The OEM fix was a gland type nut, but the short splines on the shaft still let 5th gear slide half way off the splines. When you apply pressure to a shaft on half a spline, the shaft deflects just like a torsion bar. Deflection increases pressure on the nut, and even the new nut will not hold for very long.

 

You CANT be serious - holy crap....first time I heard of that. Great, something else to worry about besides fuel pressure...

 

Sorry, but I'm sure that the problem doesn't go beyond '99.
A couple years ago talking with a very high volume dealer shop manager and with Cummins NW they said they'd had very few '99s come in with KDP damage and absolutely none beyond '99.
Starting with the late '97s Cummins started using thread locker on the case to block bolts, you rarely find any that have worked loose after that.