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Thanks GAmes... I do have a 5th wheel hitch installed in the bed. It is a Reese Signature series 18K hitch. Removing the 4 bolts that hold the pucks in isn't a problem. I was thinking that I could undo the forward bolts and remove them. Loosen the rear ones enough to jack the front of the bed up...

Thanks GAmes and Mule! Been thinking about several things, one is 'what's inside the tank' - is the fuel module/in tank filter still good? Is there any sludge/algae/crud in there? Draw straw as well, is it still good? When it happened this time, again I was @ > 3/4 tank. I remember still...

UPDATE: After I made the correct adjustment, I decided that it was quite easy to pull out the newly installed OFV and measure it's opening pressure. It measured ~14-16PSI after several attempts/measurements. So, I replaced that one with the one that I had previously purchased from TorkTeknology...

Sounds like it could be either a "grounding" or "power distribution" issue. Could also be defective or bent pins in the connectors @ the PCM. In the wiring diagram, there is a fuse F14 that seems to commonly feed much of the instrument cluster...

Thanks GAmes!

Just picked up the truck from the shop. They could not find anything wrong with the truck. I asked the to do additional tests on the fuel system, vacuum test- lift pump to tank, passed in spec. < 4 in. Hg. Fuel Pressure @ spec to the filter/injection pump. 27PSI. Fuel Return line, no...

Thank you Mlee!

Thanks Bill. I will ask the shop to specifically check the (new) OFV out. Something gong on in that arena, for sure. I mentioned earlier that, not every time but several times anyway, when the foot is on the GO pedal a little hard - the pressure drop to ~11-13 PSI. So, I guess that is the only...

Taylor Ham Hell ya!!

From Joe G's fuel system post: "The overflow valve looks like a banjo fitting, but it contains a pressure valve. The type shown in the picture has a spring, a steel ball, and a washer shaped like a tiny derby hat to regulate pressure in the injection pump. This is essential so there will be...

When mine went out several years ago, it got replaced with a 1.4Kilowatt unit. It didn't last to long either, maybe 6 months. Did some research in the -96' FSM and it calls for a 2.7 kilowatt unit for diesel applications. Currently running the NAPA 2.7 kilowatt unit now for >9 years.

Thank you again BigPapa! Not ruling anything out at this point. Could still be an in-tank module issue, I guess. The previous service guy had smoke tested the lines from the tank to the lift pump and from the P7100 return to the tank. Looks like the rubber portion of the return line got...

BigPapa, the tank was @ 3/4 full. Flat and level travel w/39' 5th Wheel in tow. Speed was 61~63 MPH, light rain and about 58* ambient outside. EGT ~950* Boost ~5-8PSI (that's why I say flat travel, not pulling a grade at all). Engine temp ~160 transmission Temp ~150 Fuel Pressure ~22PSI (but that was...

Thanks MLee. Some of the hoses got replaced during a couple of the other diagnostics/services - not sure which ones, but the 90* one between the lift pump and pre-filter for sure and the return fuel line from the P7100 looks new because I pinched it yesterday (as mentioned above). I'll check the...

Interesting, thank you!

Thanks GAmes. I will carry some water with me :) Assuming that I'd dose it prior to priming it...??

Thanks Big Papa. I was rereading that greater than ever post on the 12V fuel system. I went out and "pinched the return line" and the pressure went up from ~18PSI to ~27PSI (was looking through a mirror positioned on the dash) and the idle increased maybe 200~300 RPM's. Because this was the...

My first post because I've been able to glean the needed info from all the threads previously. The truck; `96 long bed 3500 dually. 12 valve. What's lead me to this very knowledgeable forum: Back in July; engine died...side of the road. Truck on hook. diagnosis; lift pump failed. Replaced...

TDRadmin, Having trouble trying to view a past issue. A Windows Security box comes up requesting login info. I'm already logged in and it won't accept what I put in???? What am I doing wrong? Thanks in advance for the help!

Just an update to the failure I've experienced here. Found a shop that would repair it - essentially, weld and plate it back in place. They did an excellent job!!! The welder, said that it's been a couple years since he'd seen this type of failure, but it was normally on the steering box...