Engine/Transmission (1998.5 - 2002) 99 fuel filter mount issues

[Kirwin]

I have a friend with a 99 2500 that has a leaking fuel heater on the fuel filter mounting head. The plastic fuel heater on the filter head has over heated, partially melted and cracked. Now, as you would expect, the truck starts hard due to loss of prime and has a slight fuel leak. I have researched the part and have discovered that this is not a Cummins supported part and it was not made by Fleetgaurd either. The bean counters at Dodge got a vendor to bulid them a fuel filter assembly for the 99 models and they are no longer making the fuel heater assembly. Dodge sells you an $1100 retrofit kit that installs the 2001 style filter head assembly to repair the cracked plastic piece of **** that Dodge had made. I looked at the FASS set up but it still uses the factory fuel filter. I understand that a FASS bypass kit is available that feeds the VP44 directly but your getting close to the $1100 price that Dodge wants for their retrofit kit. Additionally I'm not sure how FASS mantains its fuel warm in cold weather if you completely bypass the factory fuel filter assembly. This is just another one of those cheaper isn't always better things that cause car companies to get a bad reputation. My buddy found a dealer that has one of these kits on his shelf and has had for nearly a year and he's trying to get a discounted price to take it off his shelf. Ken Irwin

 

[CSnyder]

VPI Remote Fuel Filter Kit

 

[MBanning]

I had the same problem with my 99, and know others have as well. You can remove the entire filter housing and open it up. On the inside, in the top there are three small torx head screws that hold the heating element. The plug on the wires can be taken apart so the wires can be pulled thru the hole in the top of the filter housing as the heating element is removed. A 1/2" pipe tap fits this hole without needing to drill it out first. Tap slow, straight, and square with some cutting oil and fill the hole with a 1/2" brass pipe plug. The plastic plug you removed from the wires can be filled with silicone and pushed back in to its place in the wiring harness and I think there is a seperate fuel heater relay that could be removed. A $2 plug and a $12 tap(if you don't have one) will stop the leak and you can buy alot of fuel additive to prevent gelling, if it's cold enough to need it, for $1100

Good luck