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post #46 of 322 Old 11-25-2013, 11:06 AM Thread Starter
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Re: John Deere 445 FD620D engine rebuild after seize

Oil screen - pretty clean.
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post #47 of 322 Old 11-25-2013, 11:23 AM Thread Starter
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Re: John Deere 445 FD620D engine rebuild after seize

In the foreground is the one sizable metal shaving found hiding under the oil screen. We'll keep our eyes open for where that might have come from as we go.
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post #48 of 322 Old 11-25-2013, 11:52 AM Thread Starter
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Re: John Deere 445 FD620D engine rebuild after seize

Extracted 16 plastic oil pump gear teeth and 8 discernible metal shavings from the bottom of the crankcase.

Shot both cylinders and the output shaft bushing with PB Blaster again. Might need to manually rotate shaft a bit to remove connecting rods, but I don't want to do any further damage if there are metal particles bound up in the cylinders or bushing...
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post #49 of 322 Old 11-25-2013, 03:46 PM
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Re: John Deere 445 FD620D engine rebuild after seize

DanielRaible,

Great thread!

I am watching with interest as I also have a 445.

Good luck with the rebuild and keep the pics coming.
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post #50 of 322 Old 11-25-2013, 04:36 PM
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Re: John Deere 445 FD620D engine rebuild after seize

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Originally Posted by home-boy View Post
That looks pretty clean. Last 425 engine I had was a black blob
How many hours did the 425 have on it and what caused it to fail?

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post #51 of 322 Old 11-25-2013, 05:27 PM
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Re: John Deere 445 FD620D engine rebuild after seize

This is one of the best theads ever! A lot of us Kawasaki owners here.

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post #52 of 322 Old 11-25-2013, 06:07 PM
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Re: John Deere 445 FD620D engine rebuild after seize

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Extracted 16 plastic oil pump gear teeth
What's the going rate from the Tooth Fairy for those? Gotta get some help in the finances don't ya.

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post #53 of 322 Old 11-25-2013, 07:28 PM Thread Starter
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Re: John Deere 445 FD620D engine rebuild after seize

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What's the going rate from the Tooth Fairy for those? Gotta get some help in the finances don't ya.
The full oil pump assembly kit is no longer offered, but there are still a few floating around.

The gear alone is $4.75, and I would gladly pay multiple times that amount for a metal replacement.

Lost some time today running for tools.
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post #54 of 322 Old 11-25-2013, 08:53 PM
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Re: John Deere 445 FD620D engine rebuild after seize

Don't worry about the cylinders, they'll be fine. The cylinder and piston require almost no lubrication, especially on a liquid-cooled engine. Look for a cooked rod or main bearing. It might also be useful to find out what caused the gear failure if you plan to reuse the oil pump. Your pictures also point out the fallacy of periodic carbon removal- look how clean that engine was running.
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post #55 of 322 Old 11-25-2013, 09:23 PM
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Re: John Deere 445 FD620D engine rebuild after seize

I'm wondering if perhaps the stripped teeth of the gear got lodged or bound up causing the lock up rather than something seizing up.

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post #56 of 322 Old 11-26-2013, 03:22 AM
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Re: John Deere 445 FD620D engine rebuild after seize

Daniel, have you considered talking to a machine shop about fabricating a steel gear? Perhaps it is cost prohibitive, but then the engine is very valuable as well. CNC machines make quick work of complicated parts especially if they can copy a new plastic part. One problem with a steel gear is that the thermal expansion may be substantially different than the plastic. Larry
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post #57 of 322 Old 11-26-2013, 03:28 AM
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Re: John Deere 445 FD620D engine rebuild after seize

it IS costs prohibitive. most CNC shops charge $100 per hour for PRODUCTION.
my shop is over 500 per hour. that piece will take about 10 hours to reverse engineer and about 10 hours to make a 1 off model.

it is cheaper to go BUY it from the OEM.

that is just my .02 cents...
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post #58 of 322 Old 11-26-2013, 05:11 AM
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Exclamation Re: John Deere 445 FD620D engine rebuild after seize

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Originally Posted by f350ctd View Post
I'm wondering if perhaps the stripped teeth of the gear got lodged or bound up causing the lock up rather than something seizing up.
Personally I'd pull the crankshaft and make sure all of the oil passages are clear!!


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post #59 of 322 Old 11-26-2013, 05:13 AM
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Lightbulb Re: John Deere 445 FD620D engine rebuild after seize

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Originally Posted by rscurtis View Post
Don't worry about the cylinders, they'll be fine. The cylinder and piston require almost no lubrication, especially on a liquid-cooled engine. Look for a cooked rod or main bearing. It might also be useful to find out what caused the gear failure if you plan to reuse the oil pump. Your pictures also point out the fallacy of periodic carbon removal- look how clean that engine was running.
Mic the Piston skirts as they wear down perpendicular to the wrist pin.. (They did on mine!) Tolerances are tight in the Kaws so better safe than sorry..


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post #60 of 322 Old 11-26-2013, 07:57 PM Thread Starter
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Re: John Deere 445 FD620D engine rebuild after seize

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Originally Posted by retsparky View Post
Daniel, have you considered talking to a machine shop about fabricating a steel gear? Perhaps it is cost prohibitive, but then the engine is very valuable as well. CNC machines make quick work of complicated parts especially if they can copy a new plastic part. One problem with a steel gear is that the thermal expansion may be substantially different than the plastic. Larry
This is an excellent point. Unfortunately I do not have the resources to cut a metal gear here, or I would seriously consider it. If I was still in school this would immediately become one of my 'spare' projects when I had access to machinery.

I asked a few of my machinist friends, and they basically said I can't afford to have someone else do it for me.

My plan is replacement of both plastic gears. The dealer mentioned that the only oil pump gear he has seen fail in these is when the cam gear was upgraded and the plastic pump gear was not replaced at the same time.
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