ok the kdp killed my truck ( well my brothers truck ) and we have about got it apart to repair the gear case and we are having problems finding a dowell pin , local dealer says cummins wants like 40 bucks just to ship the 2 dollar part lol . i have a machine shop at home and i can make a pin .... so does anyone have a pin in thier hand or toolbox and a micrometer to measure it with ? if i had the specs i can make a pin or many pins . or i may be forced to try and accurately measure the hole and make a pin from those measurements.
any help will be appreciated and if any of u need parts machined please ask if i can do it for u , will be glad to help out if i can .

don t.

 

Aren't you suppose to leave the dowel pin out when re-assembling?

 

No.
The pin is essential to keep the gear case and gears correctly aligned.

 

Then what are the bolts for?

 

The bolts hold it tight. The dowel pins are MUCH more accurate to align the timing cover to the block, and get the gears in precise alignment. The holes used for bolts are pretty sloppy compared to dowel pin holes. Usually, holes for bolts have 1/64 slop (.015"), dowel pins are usually .001 or less.

 

So the pin aligns the cover, the bolts hold the cover on, and the cover holds the gears on? If that's the case, how can the pin slip out and get into the gears?

Sounds like the pin realy dosen't do anyhting if it's loose enough to fall out.

 

The pin works itself out the back side of the hole... Dodge subsequently machined blind holes to prevent KDP syndrome.

sportydon: use the micrometer from your machine shop to measure the hole and make a pin to fit...

 

The pins (there are two of them) aligns the gear case not the cover. When the pin comes out it wanders around in the case till it gets to a place that something has to give way and break.
The pin, even one that is on it's way out, is still so tight that most often it is impossible to pull it out. Falling out completely is the result of endless hours of engine vibration.

Beware clarliez, I've personally seen two '99s have the pin fall out and crack the gear case

 

sportydon: use the micrometer from your machine shop to measure the hole and make a pin to fit...[/QUOTE]

um , uh , well ........... i dont have anything to measure a hole that small lol . on a better note , we did finally find a pin and i will measure it up and make a drawing for future reference .
also .. fix your KDP ... brothers took out his oil pump idler gear and part of the gear case , we are welding the gear case . hope to be finished by sat nite as we get the parts .
if u are near south georgia and need help with a kdp just holler at me , i know how to do it now !

 

Wannadiesel is the self proclaimed KDP killer, Dave ya got one layin around?
Does my 99 have the pin?

 

I know what the pin is all about. I'm just playin with you.

I recall the pin issue is with 12v's only.

 

um , uh , well ........... i dont have anything to measure a hole that small lol . on a better note , we did finally find a pin and i will measure it up and make a drawing for future reference .
also .. fix your KDP ... brothers took out his oil pump idler gear and part of the gear case , we are welding the gear case . hope to be finished by sat nite as we get the parts .
if u are near south georgia and need help with a kdp just holler at me , i know how to do it now ![/QUOTE]

Drill bits and an index work pretty well in a pinch.

 

and '99 24 valves

 

Drill bits and an index work pretty well in a pinch.[/QUOTE]

drill bits and index do work pretty well for common size holes , it appears that the pin measures .384 so the closest drill to that is a .380 or 3/8ths . if u make a pin .380 it will rattle around in a hole made for a pin .384 , that .004 is important in this application . press fits are usually in the neighborhood of from one to three thousandths ( interference vice clearance ) depending on what it is and design specs .
if anyone needs a pin made i now have the pin specs and can make one or many of em .
i also made a tool to install a new cam bearing as we had it torn down that far so we replaced it too , if any one needs the tool maybe i can help out there.
we also found that the hole in the gear case was oversize a little so i made a stepped pin to go back in it so that it would be a close fit as was designed .

 

drill bits and index do work pretty well for common size holes , it appears that the pin measures .384 so the closest drill to that is a .380 or 3/8ths . if u make a pin .380 it will rattle around in a hole made for a pin .384 , that .004 is important in this application . press fits are usually in the neighborhood of from one to three thousandths ( interference vice clearance ) depending on what it is and design specs .
we also found that the hole in the gear case was oversize a little so i made a stepped pin to go back in it so that it would be a close fit as was designed .[/QUOTE]

3/8ths is .375"

using the drill index, you make a pin the same size as the smallest drill bit that won't fit in the hole, then turn it down until it has the proper interference fit.
Since you probably don't have a lathe (or else you'd probably have I.D & O.D. micrometers), chuck your pin stock up in the drill press and file/sand it the required amount. If you go too far - no worries... just stake the interference O.D. of the pin enough and she'll plenty tight!