Anatomy of a failed 3rd Gen lift pump

[scootergmc]

So I was cleaning the garage the other day, found lift pump #1 and remembered I'd kept it in order to cut it open and see what was going on. Well, here's the results (sorry old-school dial up guys) and forgive my lack of electrical motor term prowess:



Dissected:

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Looking into the pump housing where top of the motor touches the two spring loaded metal thingies (notice anything wrong?):

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I cut down the housing even further to get a better view:

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Now I dunno what those doohickeys are called, or what they do, but that one (as you can see) was clearly stuck out of its little spring loaded tract, and had been that way for a while. I don't know how long those metal things are when they're new, but mine were almost gone as you can see. This is a pump which had exactly 56,723 miles and made it just over 5 years, mostly highway grocery getter stuff. I dunno what it means or what anything is called, but I figured I'd post it up as I hadn't seen a thread with any lift pump detail.

 

[PMould]

the round thing with the slots,is the commutator. the springy things are brushes the commutator looks in bad shape. which wore out the brushes till contact was lost,pump stopped. just worn out. my 2 cents. pete.

 

[scootergmc]

Most threads suspect engine vibration causes the pump to fail. I tend to agree with you that the pump is just worn out and wasn't designed to handle the duty- although others are still going strong on their original pumps.

 

[PWirth]

There was a discussion about a new Federal Mogul lift pump replacement earlier this year: https://www.turbodieselregister.com/forums/5-9l-engine-transmissions-2003-2007/220892-new-fuel-pump-out-03-04-5-s.html.



The linked article was: Federal-Mogul Introduces Carter Direct Replacement Fuel Pump for Diesel-Powered Dodge Ram Trucks.



That article specifically says that the new Carter P76110 pump is brushless. The pictures of the motor above are definitely a brushed motor design. It also looks like the motor failed because of the brush wear. A brushless motor would have just permanent magnets on the center spinning section and the coils on the fixed outer section. It would use a couple of sensors and a small pc board to make the motor spin. I would love to know how many of the lift pump failures were brush failures, bearing failures, or pump seal failures. If the failures are skewed towards brush failures then the new Carter pump would significantly reduce failures. Has anyone tried the new pump?

 

[04blackcherry]

I believe that is what I have now. I have a spare also. I think it's good to know that there was a design change to a hopefully more reliable unit. As far as I know Carter makes all of the replacements, no matter who's box it comes in. I bought mine from NAPA. They sell it under the P76110 Carter Number. I have only had mine on for 10,000 to 15,000 miles. I have had no issues so far.

 

[BGlidewell]

this scared me for a minute until I realized that this is not the in-tank fuel pump.