[24vBoost]

Hey Guys,

So recently I've torn my truck down (due to a cracked radiator) and to clean/replace/upgrade parts while I have the whole front of the truck off. The truck has a long list of upgrades done to it, but has been bottle necked by the lack of head studs and springs. Well I finally have those in hand, ready to go on the motor, a kit for the KDP (which I found getting ready to fall out) and so I figured while I'm here, I'd like to go ahead and get the cam and tappets taken care of. I pulled the trigger on a Colt Stage 3 and their tappets after research.

I'm super excited to get this cam in the truck along with the other parts, but I've done the reading, looked at the pictures and can't help but think how much of a pain in the *** replacing these tappets is going to be. I've found the methods of using a piece of PVC, string, a stopper and the wooden dowels, but even then, the idea of knocking out the freeze plug or dropping a tappet really haunts me. Has no one found a more effective/easier way to accomplish this? Or am I really stuck doing it the old fashioned way?

If so, what all is needed? The write ups are a little vague. I know I need:
12" 1/2" Dowl for the lifters (8" for the rearward ones
Rubber bands to hold the dowel
PVC to catch the lifters (what size pipe? and how do most people go about cutting it in half?)
String
A stopper of some sort to fit in the tappets to pull them into place. Where would I find one of these?

I am aware of the write ups already done on this subject, but any extra information available would be AWESOME before I tear into the motor. I have the proper tools, just never removed/installed a cam before.

Thanks in advance
Brian

P.S. let me know if any additional information about the job/truck is needed.

 

[cummins6sp5.9]

It'd be A LOT easir with tge engine OUT and ON a stand capable of holding 1000 safely !!!! You can remove the oil pan and get the cam out and tappets back in from the bottom. Zip tie the old tappets UP slid the cam out, OIL new tappets, ziptie them UP, SLIDE new cam IN, Pull zipties OFF reinstall head and pushrods.

 

[24vBoost]

Unfortunately, pulling the entire motor out is not a realistic expectation for me, or else that's what I would have done in the first place. Really I guess at this point, I'm just looking to find out what little things are necessary for me to get the lifters out and then back in again...

Thanks
Brian

 

[ABennin]

The PVC I cut in half with a zaw-all. I think I cut up a piece of 2" pvc. The freeze plug will be fine, just don't go jamming the tray in. I like cloths pins to hold up the tappets.

I ended up go through all my various markers and using a cap off one. I had to cut it down and it fit snug in the tappet. Drilled a hole it, ran the string(plain string I found at the hardware store)through and tied a knot.

When installing the tappets it is easier if you have help. One person can watch from the cam bore while the other works the string from up top. In order to get the tappets vertical I pulled them into the engine and when I got at a certain point. My friend pulled the pvc out and it let the tappet go vertical and he moved the pvc back in before I pulled the tappet into the block.

Use assembly lube and back when I did mine Jeff at Colt told me to use a break in additive high in Zinc.

 

[24vBoost]

The PVC I cut in half with a zaw-all. I think I cut up a piece of 2" pvc. The freeze plug will be fine, just don't go jamming the tray in. I like cloths pins to hold up the tappets.

I ended up go through all my various markers and using a cap off one. I had to cut it down and it fit snug in the tappet. Drilled a hole it, ran the string(plain string I found at the hardware store)through and tied a knot.

When installing the tappets it is easier if you have help. One person can watch from the cam bore while the other works the string from up top. In order to get the tappets vertical I pulled them into the engine and when I got at a certain point. My friend pulled the pvc out and it let the tappet go vertical and he moved the pvc back in before I pulled the tappet into the block.

Use assembly lube and back when I did mine Jeff at Colt told me to use a break in additive high in Zinc.

THANK YOU!

Those are exactly the things I needed to know. I already cut and put in place 11 of the 12 dowels (the exhaust lifter for cylinder 2 refuses to hold a dowel :help1 so they should be ready to go when I pull the cam out tomorrow. I got myself a piece of 2" wire conduit, next I just need to get my hands on a saw to cut it in half with. Think I might know someone nearby. As for the the assembly lube, I assume I can find this at like an auto parts store? I'm sure I'll be using plenty of it, so I need to find a good amount. As to the break in, when I ordered the cam, I also ordered 2 bottles of Zinc rich break in additive, so I should be good to go there.

Thanks
Brian

 

[ABennin]

I had the same problem with the dowels. I rounded the ends of the dowel by sanding it and cut the end about 1/2" to 1" up from the end with a coping saw(or any thin blade saw) in a + pattern. Makes it easier when you push them into the new tappets later also. Any auto parts store will have assembly lube.

 

[24vBoost]

I had the same problem with the dowels. I rounded the ends of the dowel by sanding it and cut the end about 1/2" to 1" up from the end with a coping saw(or any thin blade saw) in a + pattern. Makes it easier when you push them into the new tappets later also. Any auto parts store will have assembly lube.

I did the same. Made the other 11 much easier, but for some reason this one won't seem to hold a dowel. Going to try again today. Do you happen to remember how long your tray was for catching the lifters? I didn't want to wait until the cam is out to measure and cut it down.

Thanks
Brian

 

[ABennin]

Don't remember exactly the length. If you have the new cam measure and add some. I suppose you could also measure the valve cover and add 4 or 5 inches. Then cut it shorter is you need to.

 

[24vBoost]

Don't remember exactly the length. If you have the new cam measure and add some. I suppose you could also measure the valve cover and add 4 or 5 inches. Then cut it shorter is you need to.

Finally got everything cut and set up. We went ahead and went for it, removing the cam, which was actually easier than I had anticipated. Then proceeded to remove the tappets, and due to a communication error with my helper... Lost one in the motor

After a few colorful words and a few tools getting thrown around, we proceeded to remove the other 11 without fail.. So what to do now? I feel like the only right thing to do, is to lift the motor and remove the oil pan to retrieve it... Although, I'm putting new lifters in, would it be truly ill advised to leave the lifter down there? What could it really harm? Thinking I'll just have to bit the bullet on this one.. Just looking for more info..

Thanks
Brian

 

[cummins6sp5.9]

Take tge oil pan off. Tappets are heavy enough to stay down but my luck it would somehow get caught be the crank and cause severe damage. Your call !!!

 

[ABennin]

I agree pull the pan and get it out.