This is what is involved to replace the crankshaft gear on a 5.9 cummins.

It has been some time sense I did this so if I miss a step (sorry).

#1 You have to remove the support that the hood latches too.

#2 You have to remove the A/C coil (you will need new freon when it is put back on). Remove the turbo inter-cooler and radiator.

#3 Now you can get to everything, remove the fan, fan belt and crankshaft pulley.

#4 Remove the gear cover and valve cover. You don't have to worry about the engine being in TDC (top dead center) right now.

#6 Next I used a air rotary tool but I guess you could use a electric. Buy 3-4 good quality deburring bits. I cut with the gear teeth so it would not be a straight cut but works. Cut as deep as you can with out hitting the crankshaft on 2 sides. Use a chisel and hammer it should break  in half now if not cut a little more and try again.

 


One very important thing when putting back together is the oil pump. This gets installed wrong more often then you think and will fail if put in wrong. You have to make sure it is straight. It looks like it will fit in side the block but sits on top of the block. You should look at it before it is removed so you understand how it go's.
Step 1-Tighten to 8 Nm (71 in. lbs.) torque.
Step 2-Tighten to 24 Nm (18 ft. lbs.) torque.
3. The back plate on the pump seats against the bottom of the bore in the cylinder block. When the pump is correctly installed, the flange on the pump will not touch the cylinder block. I used locktite on the bolts. This calls for light torque. Do not try to do this by feel it needs to be torque correctly.

What is involved in replacing the crankshaft gear.

Instructions to replace crank gear

#5 Now we have to remove the cam gear, first thing to remove the cam gear is take the rocker arms off and push rods out. You will need 3/8 wood rod cut long enough to come out of the head about 1 foot or more. Tap with a hammer on end where you took the push rod out you will feel it go in the tappet. Pull up on one intake and one exhaust and hold them together with a wire tie. Repeat until they are all held up. Do not use rubber bands some people will tell you to do this, if fuel gets on the rubber band it will eat it up and break in about one hour. Remove the bolts in front of the cam. You can take the cam out now. You may have to wiggle and turn to get out. Remove the oil pump.

You can buy a new gear at Dodge or you can find them other places. You will need a key also, it looks like a steel pin. It only keeps the gear in the right place and does not hold anything. I could only find this key at the Dodge dealer. If you did not read (what I did wrong) you should read first I explain how to put it back on.
You can now put the cam back in. take note of the marks on the crankshaft gear, cam gear and fuel injector pump gear you just have to line up the marks on the gears and the engine timing is set. I hope this helps if you have this problem.
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