Its official, I have beat the hell out of this dead horse and continue to do so. Files uploaded below:





I included the parts book pages from the recent manual I purchased for the 7U series showing the differences that Rome K/G refers to often. S/N 7U37458 is the cutoff for plug 9B1332 vs no plug on these housings.

What I can conclude is that on the rear of the housing there is a cover casing with casting #7B5191 that may cover up the plug 9B1332. The picture with the plug up against the housing clearly shows the plug will not fit in the hole that is present in the rear of the housing. Looking at my D42T parts book, it really does not show that cover casing.

Question: Does the cover casing need to be removed in order to access the plug looking at the picture below of mine compared to one from a 7U post earlier that clearly shows the plug.

I am waiting on a couple of parts for my pinion clutch so working to resolve this plug issue I still have hanging out there.

Bernie

Maybe a soft plug is supposed to be in the bore of that hole. Parts book show that?

Not that I can see. My D42T book shows the 9B1332 plug. There are threads behind the cover casing just like on the 9B1332. A lot of 'stuff' on the rear of the housing-

The closer I looked at that plug it looks like someone hammered that plug in there and broke the outer ring off and it's pushed in a ways. Take a bushing or a socket larger than that hole and use a long bolt and try to pull that piece out. Its threaded in the center correct? Unless that was put in there from the factory to machine the fuel passage through the housing.?

Hi Team,
I decided to look at a 4G D4 Parts Book and I did find that for pump S/No/s 7P5469 to 7P13755 they use a different P/No plug (2A4242) and seal (2A3854)

It appears in the scan that the gallery bore is counter-bored to accept the O Ring Seal and the plug flange at the same diameter, this requires that the plug is only installed flush to exert the correct crush on the seal.

See scan below.
Maybe it is what you are looking for.

I seem to have a hazy recollection of trying to remove a fuel gallery plug in the rear face of a pump I did at one time and all but stripped the puller bolt/stud thread trying to remove it --I gave up at that point and said to myself that if it was that tight it most likely would not leak--the unit did not come in for or come back for fuel dilution into the pump oil reservoir.
Yes, I could have driven the plug out down the gallery with a long punch but was reluctant to due to the tightness of the plug and what I felt as mentioned above.

I stand to be corrected.

Cheers,
Eddie B.

"Thanks Edb! I think we finally have this thing solved!"

"Oh just one more thing, I forgot to mention I didn't have a parts book for that older pump housing....any how"

From the inside of the fuel chamber the inside in the back looks clean and not broken. From the rear, the diameter of the 9B1332 plug I have is larger by probably a 1/32" than the hole at the rear on the face of the fuel housing.

Looking at the parts book below, it does not appear to show the casing cover 7B 5181 I picture above on this view. There is no way the 1332 plug bigger diameter end (where the threaded hole is tapped) will fit in any of the fuel chamber holes, neither the one on the face of the housing or the rear of the housing.



I'll try and pull the plug-I'm assuming you're suggesting using the socket / bushing like a puller and use the threads to creep it out. Is there a housing model out there that makes taking the casing cover 7B 5181 off to access the plug? I've looked at several diagrams and photos and see nothing like I have.

Taking that cover off... what mess will I get into?

Thanks Rome K/G-your info is always helpful
Bernie

NO, look at edb's parts book diagram above, it shows a smaller plug that fits in there. Ignore the 7U parts book, that is NOT for your pump housing. And yes use those items for a puller or get a slide hammer to thread in the plug.

Man! I have been a PITA on this one, but could not rectify what I was seeing. I did not see Eddies post until after I last posted.

I'm wondering now if when the block was repaired the fuel housing was replaced. If you recall the lower two nuts on the housing that lie against the block were missing. The hour meter assembly is odd too. Need to take another look at that also.

Any expectation that the governor is a changeout too? Or does the D42T governor match up with the 4G housing? Also, is the 25P535 stamp on the housing consistent with the 2T and 4G?

I appreciate the help-you guys are sharp and tenacious.

Have Fun-
Bernie