Front Gear Case Removal
 

Well, over the course of the last few days we have replaced the VP44, APPS and put a new crank seal in the front gear cover to stop a leak that I've been fightin with for a long time. Took the truck for the first test run today and now that all the old oil is cleaned off of all the parts under there we found the real leak. The gear case itself is leaking between it and the engine block.

I'm hopin that when I pull the front cover back off that I will find a lose bolt that will fix this all up. but I know my luck so I'm not countin on it. My question is, what has to be done to pull these gears so I can pull the case off the block and replace the gasket.

This is from the manual I downloaded for my '01. Unfortunately when I copied and pasted, the spaced between the words were left behind.:humm:
GEARHOUSING
REMOVAL
(1)Disconnectthebatterynegativecables.
(2)Raisevehicleonhoist.
(3)Removetheoilpanandsuctiontube(Referto9
-ENGINE/LUBRICATION/OILPAN-REMOVAL).
(4)Partiallydrainenginecoolantintocontainer
suitableforre-use(Referto7-COOLING-STAN-
DARDPROCEDURE).
(5)Lowervehicle.
(6)Removeradiatorupperhose.
(7)Disconnectcoolantrecoverybottlehosefrom
radiatorfillerneckandliftbottleoffoffanshroud.
(8)Disconnectwindshieldwasherpumpsupply
hoseandelectricalconnectionsandliftwasherbottle
offoffanshroud.
(9)Removethefanshroud-to-radiatormounting
bolts.
(10)Removeviscousfan/driveassembly(Referto7
-COOLING/ENGINE/RADIATORFAN-REMOVAL).
(11)Removetheaccessorydrivebelt(Referto7-
COOLING/ACCESSORYDRIVE/DRIVEBELTS-
REMOVAL).
(12)Removethecoolingfansupport/hubfromthe
frontoftheengine(Fig.174).
(13)Raisethevehicleonhoist.
(14)Removethecrankshaftdamper(Fig.175)
(Referto9-ENGINE/ENGINEBLOCK/VIBRATION
DAMPER-REMOVAL).
(15)Lowerthevehicle.
(16)Removethegearcover-to-housingboltsand
gentlyprythecoverawayfromthehousing(Fig.
176),taking care not to mar the gasket surfaces.
(17)Removethefuelinjectionpump(Referto14-
FUELSYSTEM/FUELDELIVERY/FUELINJEC-
TIONPUMP-REMOVAL).
(18)Disconnectthecamshaftpositionsensorcon-
nector.
(19)Removethecamshaft(Referto9-ENGINE/
ENGINEBLOCK/CAMSHAFT&BEARINGS(IN
BLOCK)-REMOVAL).
(20)Removethegearhousingandgasket(Fig.
177).
(21)Cleanthegasketmaterialfromthecylinder
block.

INSTALLATION
(1)Installanewgasketandthegearhousing(Fig.
177).Tightentheboltsto24N·m(18ft.lbs.)torque.
(2)Connectthecamshaftpositionsensorconnec-
tor.
(3)Installtheinjectionpump(Referto14-FUEL
SYSTEM/FUELDELIVERY/FUELINJECTION
PUMP-INSTALLATION).
(4)Installthecamshaft(Referto9-ENGINE/EN-
GINEBLOCK/CAMSHAFT&BEARINGS(IN
BLOCK)-INSTALLATION).Alignthecrankshaft,
camshaft,andinjectionpumpgearmarksasshown
in(Fig.178).
(5)Ifanewhousingisinstalled,thecamshaft
positionsensormustbetransferredtothenewhous-
ing.
(6)Obtainasealpilot/installationtoolfroma
crankshaftfrontsealservicekitandinstallthepilot
intothecrankshaftfrontoilseal.
(7)ApplyabeadofMopart SiliconeRubberAdhe-
siveSealantorequivalenttothegearhousingcover.
Besuretosurroundallthroughholes.
(8)Usingthesealpilottoalignthecover(Fig.
179),installthecovertothehousingandinstallthe
bolts.Tightentheboltsto24N·m(18ft.lbs.)torque.
(9)Removethesealpilot.
(10)Raisethevehicle.
(11)Trimanyexcessgearhousinggaskettomake
itflushwiththeoilpanrail.
(12)Usinganewgasket,installtheoilpanand
suctiontube(Referto9-ENGINE/LUBRICATION/
OILPAN-INSTALLATION).
(13)Installthecrankshaftdamper(Fig.175)
(Referto9-ENGINE/ENGINEBLOCK/VIBRATION
DAMPER-INSTALLATION).
(14)Lowervehicle.
(15)Installthefansupport/hubassembly(Fig.
174)andtightenboltsto24N·m(18ft.lbs.)torque.
(16)Installtheaccessorydrivebelt(Referto7-
COOLING/ACCESSORYDRIVE/DRIVEBELTS-
INSTALLATION).
(17)Installthecoolingfanandshroudtogether
(Referto7-COOLING/ENGINE/RADIATORFAN-
INSTALLATION).
(18)Installthewindshieldwasherreservoirtothe
fanshroudandconnectthewasherpumpsupply
hoseandelectricalconnection.
(19)Installthecoolantrecoverybottletothefan
shroudandconnectthehosetotheradiatorfiller
neck.
(20)Installtheradiatorupperhoseandclamps.
(21)Addengineoil.
(22)Addcoolant(Referto7-COOLING-STAN-
DARDPROCEDURE).
(23)Connectthebatterycables.
(24)Startengineandinspectforleaks.

installing..............use a bit of silicon to assist the seal bud.......clean it real good too

Anybody done it.

let me clarify hehehheee

dont use silicon on the crank seal but do use it on the cover gasket to help seal it

Ya ever pulled the front gears and the case off the block.

off my sons 94...........very straight forward job

01 Dodge cummins turbo diesel TIMING GEAR Housing CTD : eBay Motors (item 360230057457 end time Feb-01-10 17:52:51 PST)

From looking at this picture, I now have a good idea where it is leaking.

Hook up the vacuum cleaner, the RTV is coming out!

Well so much for pullin the crank gear, snapped the arms off the pullers, twice and never budged.

But we think we found the problem anyway, I was missin a one of two nuts that hold the Vacuum pump in place so it wasn't sealed on the backside of the gear case. Still workin on puttin it all back together so don't know yet if this is gonna fix it.

hopefully that is it and your luck has changed my friend:w2: