Archived 1996 Dodge Fuel Issue

[LChapman]

I have a 1996 Dodge 2500 turbo diesel with a 5 speed manual transmission. When I'm not pulling my 29 foot fifth wheel trailer I have no issues with the truck. It has the Banks twin manifold package on it. I had some problems with the Gino's fuel shut off solenoid. The last one that they replaced I set at 66 millimeters. It was dropping out on the road and shutting off the fuel and only when I'm pulling my trailer. This last time we just returned from Zion National Park. It's about 230 miles from here. I had no problems with the truck going there. On the way back I thought the fuel shut off solenoid was dropping out so I tied it up so it could not drop out. It feels like the fuel is shutting off to the engine. On a flat stretch of highway the rest of the way home I kept my speed between 55 and 60 miles an hour. Even pulling a slight grade we were okay but as soon as I had a steep hill and had to pull it back into 4th gear it would start shaking violently and when you push the clutch in it would just die. Stop for a few minutes, restart the truck and then we can go on along for another mile or so and it would start shuttering and it would happen all over again. On the hill in 2nd gear I just kept my foot slightly on the gas just enough to keep the truck going up the hill and we were okay. If I tried to give it any more fuel it would shake violently and want to shut off. Has anybody out there ever had this problem? I need to know what the problem is. I put a new fuel filter on it and on the trip I pulled that one off and put another new fuel filter on it and we had a three-quarter fuel tank when it was doing this. I have an adjustable fuel return valve on it too.

 

[The patriot]

Get some gauges.
Meanwhile check your fuel cap & thinks like that.

 

[LChapman]

Thanks. We did loosen the cap, but it didn't make a difference.

 

[LChapman]

What do you mean by "check your fuel cap". Check it how? Can it be causing a vacuum. I have a Gino's locking fuel cap.

 

[p-Bar]

Did it make a sucking sound when you opened it slowly? I think you have a fuel issue put a fuel pressure gauge on check it at idle then put it under a heavy load and see what happens

 

[GAmes]

Mine has made a sucking sound since it was brand new, it is normal. There is a complete description of how the vent system works in the FSM.

OP, a fuel pressure gauge is the place to start. Then take a look at Joe G's fuel system write-up. In the mean time, did you clean the prefilter screen?

 

[crabman]

This is what GAmes was referring to:
http://www.cumminsforum.com/forum/94-98-engine/58777-joe-gs-fuel-system-writeup.html