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| First step is to remove the rad overflow bottle use a screwdriver to pop the round button Loose then just slide the bottle up and out |
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| Using the fan wrenches one for the fan pulley the other for the fan...loosen the 6 pulley bolts |
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| Now break the fan loose from the pulley hub remember this is a left hand tread to remove the fan from the hub |
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| Remove the fan belt....nows the time to inspect the belt and replace if needed then remove the fan pulley |
| Remove the alternator and carefully set it on top of the turbo tube....I also removed the bracket to access for photo's |
| Remove the fan hub and bracket |
| I removed the top rad hose (needed replacement) and the oil filler then I pulled the fan out thru the top for better access |
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| The drilling bracket is installed the housing is about 1/2 " thick I drilled almost thru then used a vacuum to remove the chips remember to cover the damper pulley with a shop rag |
| Now its time to use the countersink bit drill until you come to the stop I removed the jig to show the drill hole and countersink vacuum all the drilling chips the next step will be to finish drilling thru the gear housing remember to pull the drill out and keep vacuuming out any drilling chips |
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| After drilling thru the housing if you didnt hit the dowel pin then you can tap the hole using the supplied tap adapter last step is to install the blocking screw and apply red loctite to only the head of the screw |
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| If you hit the dowel pin then your options are to pull the front of the gear housing cover off and put the dowel back into place....sometimes you can work it back into place thru the hole that was drilled (which I have done) then install the locking screw I have heard of people drilling a hole in the front cover and tapping the dowel back into place then filling the hole with JB weld |
| Note You will need metric wrenches and a cordless drill the complete job took 2 1/2 hours to do 2 trucks |
| Fixing the KDP On Dodge Cummins Motors Using a vacuum puts very few drilling chips into the motor which fall harmlessly into the oil pan |
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| This is the Jig Kit its complete with instructions...all you need are a few hand tools and a vacuum or air pressure |
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| Click here for KDP instruction sheet |
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| This is a photo showing the blocking screw and how it covers the dowel pin from coming out |
| Over view of front gear housing and dowel pin |
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| Click for speed ratio chart And tranny temp chart |
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| A Broken Housing |
| Click for dodge short bed turning with a trailer |
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| Phantom Cycle Inc |