Attention: TDR Forum Junkies First off this might be a little long. Im going to start off with a little background of myself. Im 23, i was a BMW Master tech before making the switch to a Dodge dealership in 07. I figured i would write this for people having the same issue. Information is a valuable thing. I own a 95 3500 5speed. It has a new motor, trans, turbo, complete suspension, and power steering system. I purchased this truck in feb of 07. It has alwys had an issue when starting in cold weather. When i start it, it sounds like one of those old hit and miss motors. When i got the truck i adjusted valves and had pump timing set at 17*. I fixed all intake air leaks. I then had a friend of mine, kieth summers, at MCS Midwest Performance Diesel do a conservative turn up to it. Turn star wheel and move the stock plate. Ever since i bought the truck i wanted to put a plate in it. But there was stuff i wanted to do to it first before just adding fuel. I added a k&n and 5 inch ss exhaust.
Well at high RPM's the truck would dogout and just seen like it is running out of fuel. So i got on the TDR and found what lines to check, where there at, ect. . So i checked all fuel lines for leaks. I determined some looked questionable. I also figured it could be my lift pump becoming weak. So i purchased a FASS system from MCS. (its the 90 or 110 gph one. I cant remember) I like the filters under the bed, rather than in the engine bay. Easier to get to.
So i get that on, all new hoses, pump, and filters. I go drive it, still cutting out. WTF!!! Well after a while of driving it it started cutting out. Then i flow tested and put a pressure guage on the fass. turned out ok. Then i bought a #5 plate. WOW!!! what a difference a fuel plate makes. It was running good for a few days but it still felt like fuel wasnt getting to the motor. Finally checked pressure between fuel pump and injector pump. 20PSI. So I shimmed the return valve to 40PSI. Again a noticeable difference for th better. By this time when you row the gears, when it goes into third it just falls on its face and blows white smoke. Let off for 5 or 6 seconds back to normal. taped the fuel pressure gauge to the windshield and test drove. When it cut out it went from 40PSI to 0PSi. WTF!!! All lines are new, new FASS, and new filters.
So finally pulled the 3500 in the shop and dropped the tank. (it had to be the only thing left) (I was getting ready to send out my p pump to get rebuilt) pulled out the old sender. Did it look bad. the float was all eat up. There were screws drilled in the side of the sender, and from fuel sloshing around caused ther to be metal shavings in the tank. Which i cleaned out. the old sender had crakes in the supply line sucking air, even with a full tank. I was going th just replace a hose but the sensder was in bad shape. I had some senders from HPCR's that we have been retrofitting. so i put one in. The only thing is that my fuel gauge doesn't work. I dont know which wires i need to switch, or if i can make it work at all. But anyway, it started up and run like a dream. after a year this truck finally runs right. Sorry for the long drawed out story but man im just glad my truck is finally running the way it should.
Well at high RPM's the truck would dogout and just seen like it is running out of fuel. So i got on the TDR and found what lines to check, where there at, ect. . So i checked all fuel lines for leaks. I determined some looked questionable. I also figured it could be my lift pump becoming weak. So i purchased a FASS system from MCS. (its the 90 or 110 gph one. I cant remember) I like the filters under the bed, rather than in the engine bay. Easier to get to.
So i get that on, all new hoses, pump, and filters. I go drive it, still cutting out. WTF!!! Well after a while of driving it it started cutting out. Then i flow tested and put a pressure guage on the fass. turned out ok. Then i bought a #5 plate. WOW!!! what a difference a fuel plate makes. It was running good for a few days but it still felt like fuel wasnt getting to the motor. Finally checked pressure between fuel pump and injector pump. 20PSI. So I shimmed the return valve to 40PSI. Again a noticeable difference for th better. By this time when you row the gears, when it goes into third it just falls on its face and blows white smoke. Let off for 5 or 6 seconds back to normal. taped the fuel pressure gauge to the windshield and test drove. When it cut out it went from 40PSI to 0PSi. WTF!!! All lines are new, new FASS, and new filters.
So finally pulled the 3500 in the shop and dropped the tank. (it had to be the only thing left) (I was getting ready to send out my p pump to get rebuilt) pulled out the old sender. Did it look bad. the float was all eat up. There were screws drilled in the side of the sender, and from fuel sloshing around caused ther to be metal shavings in the tank. Which i cleaned out. the old sender had crakes in the supply line sucking air, even with a full tank. I was going th just replace a hose but the sensder was in bad shape. I had some senders from HPCR's that we have been retrofitting. so i put one in. The only thing is that my fuel gauge doesn't work. I dont know which wires i need to switch, or if i can make it work at all. But anyway, it started up and run like a dream. after a year this truck finally runs right. Sorry for the long drawed out story but man im just glad my truck is finally running the way it should.
