3rd gen problems, need some insight guys!!

[pwerwagn]

Ok so I bought a 3rd gen a while back, and kept the 12V incase i didnt like the 3rd gen. Well all was good, so the 12V went to a new home last friday. Then this thurs, the 3rd gen kills over!!! haha



So anyways, here is what happened. I was wheeling, pointing down hill. had about 1/8th tank, the truck died. I figured, no biggie... pickup got uncovered. So It restarted and i hauled arse down hill to flat ground, let it idle for a few minutes to let fuel back in the lines.



Then I decided to leave, and when i got on pavement and tried to accelerate it would cough and sputter and die. Then it would restart... go about 1/4 mile then sputter and die. Every tiem the distance got shorter, I made it about a mile total. Then it wouldnt start at all.



So I hitched a ride home, and went back and towed it. I stopped at the gas station and put 10gal in it, but it wouldnt start still. Then, right when I got it int he driveway, I cranked and it started and ran fine. I drove it around the block, and no problems.



Then last night, I went to drive it and it sputtered, so I just took it home. I guess it could still have air in the lines but i didnt trust it.



#1. Are the sending units known to just read wrong on the fuel level all of a sudden (less than a week earlier I had it down to E and it still ran... ).



i know this isnt the engine forum so im just gonna ask about the fuel gauge... .



thanks guys,

Jeff

 

[pullya]

IMO The first two things I'd look at are the fuel filter and the lift pump.

Jay

 

[sag2]

When you pull your filter see how much junk is in the filter housing. When the lift pump filter in the tank gets plugged with algae or other bad stuff they will starve for fuel once the level gets below the top of the little bowl the pump sits in. So as pullya said, filter then lift pump.

 

[EDankievitch]

I'd bet your lift pump pumped it's last ... ... You have a few options the fass system or replace it with the same pump from Gino's or you can do the in tank update from Dodge. Open the water drain on your fuel filter have someone cycle the key to the run position, Oh I should have said to put a container under the drain hose to catch the fuel, you should get good flow not a dribble if yo get just a dribble then I'd start thinking about replacing the lift pump.

 

[CDonaldson]

Hey Jeff.



I have been noticing a lot of guys talking on many forums about 2003/2004's and lift pumps dying, yoyu might just be at that point in time???



I'd start with the fuel filter as well. Then lift pump.



Sometimes I wonder about my fuel gauge, maybe it's only a relative thing like the temp gauge?? (Sarcasm on). But the fact is, even when my fuel gauge needle is at the same place when I fill up, there ARE some differences of more than a couple gallons either way. My fuel mileage is consistent as far as miles traveled to that point and hand calcs come out right, but the gauge does not always READ the same for same amounts of fuel.



CD

 

[pwerwagn]

I pulled the lift pump, its a gonner... . smokes when I hook it to a battery... haha.



How is everyone bypassing them since the filter housing is fed by the pump?



Its time for an Air Dog of Fass I guess. Shoulda kept the one off the 12V... .

 

[TSPowell]

How is everyone bypassing them since the filter housing is fed by the pump?QUOTE]



This is what I did when my lift pump died:



https://www.turbodieselregister.com...walbro-remote-dual-filter-install-w-pics.html

 

[pwerwagn]

Cool!! I might just do what you did, since I already have an extra new walbro from a Jeep project a while back.



BTW, I posted this prob on a few forums and TDR has the best/most responses... as usual.



--Jeff

 

[CDonaldson]

Jeff.



Seems to me that I saw a replacement pump, aftermarket, on Genos website for your truck. It was reasonably priced. You might want to look there.



The Walbro has been used by many, sounds like it has done a good job. If you are thinking about adding some power mods to that new to you 3rd gen, then the Walbro, FASS, AirDog all are what people are using along with a BIG LINE kit to help with the additional flow.



CD

 

[pwerwagn]

Yeah, I think im going Air Dog.



Already running a smarty, and doing a turbo/trans in the next few weeks. might as well do it right!!



This makes me miss my old 12V though. :{



--Jeff

 

[RVTRKN]

pwerwagn, What version of Cummins engine do you have? in 04 there were several. If it is the 325/600 then your injector pump is probably OK, but if its the early version, then possible Injector pump failure caused by the lift pump going dry. A good friend of mine lost his injector pump a few years ago and D/C warranty covered the cost. A month ago he was at Glamis Dunes when his lift pump failed and it damaged his new Injector pump. That is a known possible failure when the early 3rd gens lift pumps fail. Don't mean to rain on your parade, but it is a possibility.

 

[moonranch]

Jeff,
Sorry I did not get back to you sooner, I was out of town this weekend. It looks like most of your questions have been answered. But as far as the fuel level sending unit; when I installed my tank vent I knew I would have to drop the tank. So I ran the truck on empty(with a spare 2gals in the bed) until I reached about 100 miles, without ever running out of fuel. When I pulled the tank there was still about 1. 5 gal left. My guess is that when the gauge reads empty, it means close to empty on a very steep hill.

 

[pwerwagn]

I have the 04. 5, 325hp truck. Im hopin my CP3 is still good!!



Should find out shortly!



Thanks for the info James. I have ran mine about 60 miles past the point the overhead said "DTE-0" with no problems, then it still only took 31 gallons.

 

[RVTRKN]

pwerwagn, you should be fine, I lost my lift pump as many other owners have and no damage done. I had repair done under warranty and they installed the in tank pump, they gave me the old assembly from the tank in case I want to install a Fass system. If you pay for repair you should go with the Fass system, that way you won't have as big of bill due to tank removal.

 

[pwerwagn]

Yeah, im putting a FASS on it. Even though its warrantied... a dealer/shop never has and never will touch my truck.

 

[JRMora]

Jeff,



Glad to hear you're getting things right. My lift pump cratered when I was driving to Denver. About 4:30 in the morning just south of Raton to be exact. I knew it was going as I had less than 5 psi of fuel pressure. I was hoping to limp in, but no... Had to get the truck towed to Trinidad to get it fixed. They put in the in-tank LP. Ever since then, If I run the overhead to "0", I can put 37+ gallons of fuel in the tank. I'm mindful now. It must be how they reset the sender in the tank upon reinstall.



I've put another 30k miles since the new pump was in and so far, no probs. I had planned on doing the FASS, but I was stuck on the road with no tools, no parts, and a desire to get home. Besides, it was covered under warranty.



I'll deal with it another time.



Juan

 

[pwerwagn]

Yeah, I feel pretty fortunate that it broke where it did so I have the opportunity to just do the FASS on it.

 

[RGardner]

I believe that mine just quit as well, over the weekend, the truck would just die unexpectedly but I managed to limp home. When I got home I replaced the fuel filter, just hoping that it would fix the problem. No such luck, I could not get the pump to prime the filter. Calling in the morning to see if my extended warranty is still good after Chrysler went bankrupt.