Engine/Transmission (1998.5 - 2002) Dodge pump failures

[DBartoli]

I need input from people familiar with the 2nd generation lift pump and injection pump cures. I have a 2002 2500 2wd HO K&N Jake 4"banks exaust 6spd 3. 54. Bought it new with 7yr/100,000mi warranty. Warranty replacements of lift pumps at 42K, 43K, 65K & 92K plus injection pump at 43K.

When lift pump was replaced at 92K I asked the dealer if I could add a carter pump to increase the flow to the injection pump. Was told no, it will negate the warranty. 102K injection pump failed. 100% on me $2105. Asked again about warranty on new pump. Told 12mo or 12K. Asked about additional in line pump and again told it will void warranty. Other than being totally unreliable, I like the truck and have had no other problems. Can someone give me information on how to make this engine reliable. 6 pumps is absurd in 102K.

I have found the factory consumer assistance people to be snakes. I was told when I brought in this vehicle they would pick up the majority of this repair. The day of pick up a supervisor change the rules.

I would like to know what options are available to increase reliability, what is the new expected pump life and what does each approach normally cost?

Has anyone ever put together a class action lawsuit against Dodge for this 4. 5 years of lemons? There are millions of these on the road surely someone has a cure for this junk. I don't trust this truck past my AAA tow distance. Post your replies or contact me direct at -- email address removed -- .

 

[stownsend]

???

“Other than being totally unreliable, I like the truck and have had no other problems. ”



Are you being sarcastic? If I had a vehicle that was totally unreliable, I’d get rid of the pig! The reason I bought a Dodge CTD is that it is TOTALLY reliable.



I have never heard of so many problems with fuel pumps. You’ve got something else going on that is not being diagnosed properly. Try a new mechanic.

 

[MFranz]

Lift Pump Blues

Try a search with the keyword Lift Pump. Your going to be amazed at the amount of info and options. A few of those being AirDog,FASS, A Carter Low pressure Pusher Pump and the RASP system by K. O. Engineering. I went with the AirDog. I only have a few hundred miles on it so far. But the fuel pressure gauge doesnt move below 15psi. Kind of pricey. I paid $800 and since then it has gone up even more. Good quality and workmanship.

The Class Action Lawsuit sounds interesting. There certainly seem to be enough out there with this problem.

Good Luck

Mike

 

[rkressg]

I have never heard of so many problems with fuel pumps. You’ve got something else going on that is not being diagnosed properly. Try a new mechanic.

You must not hang out in the 2nd gen 24v forum very often. Just a quick glance and I see about 6 of the top 20 posts in some form related to fuel supply issues and IP failures.



I personally went through 8 lift pumps in 50,000 miles. I have run a FASS for the last 53,000 miles and have had virtually no problems with it.



Remember, even the ancient Greeks figured out that pumps work better when they push and not when the pull. You think the engineers at DC could understand this basic concept.



DBartoli, if I were you, I would have made some loud noise to DC customer service if they would not warranty your VP44 at 102k with the warranty/service history on your truck. A good dealer would have warranted that part for you.



Also, I can only strongly suggest replacing and upgrading your fuel supply system. The fuel is utilized to not only run the engine, but to lubricate and cool the VP44. If there is not sufficient fuel available for the pump, it will destroy the internals of the pump. You should make this modification ASAP before you damage the new VP44.



Get a good quality mechanical fuel pressure gauge. Look for something like an ISSPRO gauge. Steer away from the electrical gauges because diesel fuel tends to destroy the sending units and they become erratic.



Finally, where are you located? There are many great sources of information available here, please look around, it is about the best money spent to be a member here.

 

[GKinney]

pumps????

DBartoli, it does sound like a lot of pump replacements. I agree you should seek another mechanic, wether it's at DC or a good diesel shop. Makes me wonder with all the lift pump failures if you might have a restriction in your fuel tank module or fuel lines??? That is another great search to do on this site, wealth of great info to be found. I bypassed my module with a 1/2" stand pipe in the tank feeding the fass with plenty of fuel. No problems since,,, knock on wood. Good luck and I hope you find some help!!! gary

 

[OPoole]

Anybody looking for a RASP? Let me know Thanks

 

[JRihani]

Is anyone selling the RASP system in Indiana? The install looks a bit daunting...

 

[Gary - K7GLD]

You can believe the DC mechanics, and keep replacing part$ - or:



1. Install some upgraded fuel supply system to the VP-44 - like the RASP, FASS, or a MUCH less expensive Carter pusher back by the tank.



2. Provide maximum practical fuel filtering to reduce pump damaging garbage going thru precision parts.



3. RELIGIOUSLY use a good brand of fuel additive that provides lubricity as it's main ingredient - most also improve cetane rating and clean injectors as well.



The above will CERTAINLY improve your chances of greatly reduced fuel system failures - but as with anything mechanical, things can still go belly-up without warning.



I have had 40,000 trouble free miles using the stuff listed below in my sig...

 

[OPoole]

Install not bad with my line kit all fittings are marked. The main part is allready together. I have pictures on my web site. www.powerbypoole.com

 

[fox]

If any 98. 5 thru 02 ISB Cummins does NOT have a fuel pressure guage, you are playing rulette. Bosch, not Dodge needs the class action suit.

Dodge is working , ( finally) on a in tank kit for out trucks.

Fast to accept this aren't they?



One more thing, I have had a lot of issues with the VP44 on my truck but recently have Soy-diesel in it. It is a 11% mix, and this truck has NEVER been this consistent in performance.

Smokes less and ALWAYS smokes the same foe the given load. It would belch and smoke heavy at times, and ( I think ) have a timing issue. It now is a very good and consistent performer. I will post a thread on it tomorrow.

I cannot pull the fuel pressure below 8 lbs.

 

[mhenon]

DBartoli, it does sound like a lot of pump replacements. I agree you should seek another mechanic, wether it's at DC or a good diesel shop. Makes me wonder with all the lift pump failures if you might have a restriction in your fuel tank module or fuel lines??? That is another great search to do on this site, wealth of great info to be found. I bypassed my module with a 1/2" stand pipe in the tank feeding the fass with plenty of fuel. No problems since,,, knock on wood. Good luck and I hope you find some help!!! gary

BINGO!!! "A" lift pump problem is one thing. Losing one pump after another tells my there's something else going on. Gotta be a restriction up-stream of the LP.

Mike