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1st Generation Dodge Cummins 89-93 Discussion of 12 Valve 5.9 Liter Dodge Cummins Diesels with Rotary Injection Pumps

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Does anyone have a brilliant idea for removing the crankshaft timing gear. You can see in the photo that it's spun on the crankshaft and sheared off the alignment pin. (Yes, it was a killer dowel pin that caused this!!!) There's about a 1/8" to ... JOIN NOW TO REMOVE TRACER

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  #1  
Old 10-30-2013, 11:13 AM
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Default Crankshaft timing gear removal.

Does anyone have a brilliant idea for removing the crankshaft timing gear. You can see in the photo that it's spun on the crankshaft and sheared off the alignment pin. (Yes, it was a killer dowel pin that caused this!!!)



There's about a 1/8" to 3/16" space between the gear and the front of the block.

Is there a Cummins tool for this?

Here's a link to a similar tool a guy built to pull a BMW gear. I'm not going to pay a machine shop to build one but if anyone has already made one I'd be willing to pay to borrow it. http://www.isettadoc.com/files/gearpuller1.pdf

I'm going to pull this engine so if necessary I'll remove the crank and have a shop pull it off and press it back on with a new alignment pin.

Nevadan's Sig:85 Jetta 1.6 TD
57 Mercedes 180D (45hp!)
85 Volvo 2.4TD (6 cyl VW)
91 Dodge W250 4WD 6BT
87 VW Quantum 4WD to get 2.0TD soon.

Last edited by Nevadan; 10-30-2013 at 11:15 AM..
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  #2  
Old 10-30-2013, 12:58 PM
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you should be able to put a welding glove over the gear and use a big pipe wrench and spin it back. you should be able to pull it off with a reg gear puller. that's how I have done them.
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Old 10-30-2013, 01:35 PM
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Good idea using the leather over the gear.

I still can't get the puller onto the gear because there's not enough space between the gear and the block. I'll experiment grinding down the puller jaws to get it behind the gear.
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Old 10-30-2013, 02:57 PM
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use a punch and 4 lb sledge ... then buy a new gear ..
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Old 10-30-2013, 03:32 PM
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Originally Posted by 4x4manonbroke View Post
use a punch and 4 lb sledge ... then buy a new gear ..
I was thinking the same.. im kicking myself right now. I had a gear and crankshaft and the gear was off. I got tired of seeing it and tossed it out!!!! that would have worked good for him!!!
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Old 10-31-2013, 08:25 AM
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Are you saying use a punch to break the gear off the shaft? Or will the gear spin off? Or a combination of turning and breaking it off?
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Old 11-03-2013, 10:41 PM
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I looked at the pics and it looks like if you used a punch and hamme it would re-allign with the key and then yo ucould heat with a torch ( Carefully not to heat crank much ) and carefully use a set of bars to work off ..... of course having all the right tools has never happened to me so this is back woods engineering from my head ... i have done a few engines like this .... I also have used a die grinder and carefully cut through the gear and the drove a small hardened chizzel into the gear to help seperate it a bit .... worked ok ... gonna take patients, and a level head my friend ... if you get pissed off ... take a break .... I know how hard they can be .... keep posted ... i'm watching
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Old 11-04-2013, 10:46 AM
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I'm sort of a back-woods mechanic so I understand exactly what you're talking about. I pulled the KDP killed engine this weekend so I will begin working on it once I get my "New" engine installed. It's going to be several weeks before I get to it but I'll post here once I determine the solution.
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Old 11-04-2013, 03:29 PM
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ok ... kew l ... look forward to it being a fun time... LOL
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