Engine/Transmission (1998.5 - 2002) Cracked Lift Pump??

[OutbackDiesel]

Has anyone heard of or experienced a cracked or otherwise leaking lift pump? I replaced my lift pump about a year and half ago. I have had no trouble with it until now. The leak is enough to make me nervous since it ends up all over the starter and anywhere the truck is parked for a few seconds. The lift pump is wet seemingly from lower down on it somewhere. The top where the banjo's are is or seems to be dry. Kind of stumped on this one. Thanks for any help.

 

[Sticks]

First I would take some brake cleaner and spray the pump down to get all the fuel off it, (keep a thick rag on top of your starter to catch the drippin's) then bump the starter (do not start the truck) and crawl underneath your truck to see where the fuel is dripping from while the LP cycles. Find out where you need to be laying and looking before you bump the starter, so you can get to it right away.

 

[Gary - K7GLD]

Outside of the fittings, only 2 likely sources of leaks - the gasket at the pump plate where the pump bolts to the bracket, and possibly a failed O-ring seal where the pump motor housing is crimped to the pump body. Sorta unlikely that anything would actually crack...

 

[jpmutt]

I have experienced the same thing. I replaced the lift pump and the next day or so I could smell fuel. I started looking for a leak and thought I left something loose. This was back when you had to call STAR (DC's technical hotline) to get a transfer pump ordered. I found the lift pump leaking around the top portion of the motor body. It was cracked. The guys at STAR said this was impossible. I have found two others that have done the same thing. I think it was caused when the body was crimped around the pump housing. Just an idea.