FASS 95 install

[WCPoe]

Well I bought a FASS 95 to upgrade my fuel system and finally got out to the shop to do the installation. Put the truck on the lift and started calculating what it would take to get it installed.



After rereading the FASS instructions several times I thought to myself that the mounting location seems vunerable being right in front of the rear wheel hanging kind of low where debris from the front wheel get thrown up.

I'm just not happy with this arangement so I looked around and thought to myself that I could weld up a much better bracket and mount it inside the frame rails near the trans crossmember in front of the fuel tank.

:-{}

Anyone care to comment on their experience or alternative mounting solutions?

 

[rscurtis]

Does your truck have the fenderwell liners? They will protect the pump.

 

[Buffalo]

Seems to me that I recall hearing that you are not supposed to weld on these new frames. I could be wrong about that but, I would check before welding.



Joe F.

 

[WCPoe]

Does your truck have the fenderwell liners? They will protect the pump.

Yes, I installed the rear liners when I bought the truck. But it looks like the fronts throw the stuff right back there as well even with the mud flaps which do help somewhat.



Buffalo, -- I wasn't going to weld onto the frame, just fabricate a bracket and bolt it up to the inside of the frame. I noticed a clamping style frame bracket on someones Airdog pump writeup. Since mines 2WD there's all kind of room just rear of the crossmember inside the frame. Looks like I could cut a piece of 3. 5 inch angle iron and bolt it to the flat upper surface of the crossmember extending back about 8 inches and bolt it to the flat bracket that Fass provides.



I also noticed the fuel supply line is right there as well. I even thought about cutting the existing steel 3/8 supply line and plumbing it to the pump with a very short piece of the FASS hose and a compression fitting. This would forego the long rubber hose running back to the tank.



I still debating this upgrade but thanks for your input.

 

[KBertetto]

I mounted my FASS 95 in the Specified location, but it was a real pain in the arse. If you have a short bed, all I can say is good luck, the FASS provided instructions are absolute garbage, throw them away. What I can tell you is that I have the wheel liners installed, and so far nothing tragic has happened. Also of note, I inspected my set-up after I read your post and found no paint missing or any damage what so ever on the Pump/filters. I have only had mine on for about 10K or so, but it doesn't seem to be taking any direct hits from road debris as of now.



Bert

 

[Buffalo]

WCPoe,



I didn't realize that you already knew about 'not welding to the frame'.



Like you, when I installed my GDP Walbro-392 pump on my truck, I built an aluminum plate which, I 'clamped' onto the frame. It worked very well. I had to use the aluminum plate because I had to install the pump along with two electric valve systems to accomodate the auxillary fuel tank I have installed. Designing & building this system was getting pretty close to approaching my outside level of mechanical expertise. I'm just not that good at this stuff. Not as clever & talented as others.



Joe F.

 

[steved]

I have over 100k on my 95/150 without any issues... no fender liners.

 

[WCPoe]

Well, I got industrious and fabbed up a bracket to mount the FASS to the crossmember and will position the FASS just barely behind the trans crossmember on the driver's side of the tunnel. The FASS fuel filter bottom doesn't hang below the crossmember and should be well protected. There were two existing holes in the nearly 5 inch wide crossmember so I will be mounting the bracket there but added an auxilliary support strap to the frame which will allow you to remove the crossmember and leave the FASS in place.

I still need to drill a couple of holes in it so it will bolt to the flat predrilled plate that FASS has you mount to the pump. The rubber isolator they supply will sandwich between my bracket and their flat plate. I'm going to use nylock bolt/nuts to secure these two together.

I still want to cut into the existing steel fuel supply line which runs down inside the frame rail instead of running rubber tubing all the way back to the tank. I never liked running rubber hoses all over the place and I may be able to use the front part of the OEM steel line to get the fuel from the pump up to or close to the CP3. We'll see.

On another note, I have a question or two.



Do you leave the old filter housing/ pump assembly inplace? There seems to be other steel lines and such attached and I'm not sure what all their functions are. I need to study up on this

Updates to follow.

 

[DaveHess]

WCPoe: I mounted mine in front of the drivers rear tire as instructed but I had to do some serious grinding on the bracket to get the pump to clear the filler neck. I fabbed up a set of rubber flaps. One is mounted in front of the leaf spring perch and one at the front edge of the bed. So basically my FASS is between two rubber flaps with the bottom open and exposed. Stays pretty clean and no damage. I have a hissing sound coming from the pump area that I cannot locate. Doesn't seem to affect performance but it is annoying. I posted but received no reply, Lowfly in particular. As for your question about removing the OEM filter, GDP makes a kit. I purchased but have not had the time to do the mod yet.

 

[WCPoe]

WCPoe: I mounted mine in front of the drivers rear tire as instructed but I had to do some serious grinding on the bracket to get the pump to clear the filler neck. I fabbed up a set of rubber flaps. One is mounted in front of the leaf spring perch and one at the front edge of the bed. So basically my FASS is between two rubber flaps with the bottom open and exposed. Stays pretty clean and no damage. I have a hissing sound coming from the pump area that I cannot locate. Doesn't seem to affect performance but it is annoying. I posted but received no reply, Lowfly in particular. As for your question about removing the OEM filter, GDP makes a kit. I purchased but have not had the time to do the mod yet.

Dave, I think that was a good move installing those rubber flaps. I noticed your truck is a long bed which helps because the frame bracket you mounted the FASS to has much greater clearance that my short bed. The FASS instructions for the short bed want you to mount the pump on the last cab support bracket as opposed to the long bed instructions which tell you to mount it to the first truck bed bracket. I tried fitting the pump assembly to my cab bracket but without extensive mods I didn't see any way this was going to work.

#@$%!

I should finish the last few details on my homemade bracket today but probably won't have time to finish the rest of the pump install untill Monday.



Concerning the FASS instructions about the fuel supply line hook up it shows the line from the pump going direct to the CP3, which looks OK. But with all those other existing lines going back to the filter assembly is ther a possibility fuel will back flow out the old pump???? Has anyone eliminated the OEM pump and still run the new fuel supply line through the existing filter keeping it in place, thus retaining the fuel heater and water in the fuel sensor????



I think Geno's has some kind of fitting that fits on the filter housing that eliminates the OEM pump but I'll have to wait until Monday to be sure. I may need to check with GDP as well.

Heck, my truck has been sidelined too long and I still need to get my boat out of the water and get it winterized. This pump thing has become a real pain and I still have the possibility of a bad Rail Pressure Sensor, although there hasn't been a return of the P0192 code since I initially cleared it. :{

After this ordeal I need some counseling. This has been so frustrating I thought I would sell the truck and buy a new 2010 HD2500 whereupon I would swear on a stack of TDR magazines that I wouldn't modify it in anyway. Wait what am I thinking, I only have about 50,000 miles on this "Garage Queen".

 

[DaveHess]

WCPOE: I finally figured out to attach pictures (I hope). Here goes.....



View attachment 73842

View attachment 73843

 

[DaveHess]

Those pictures were taken tonight. The pump assembly has been on the truck for about 6 months now and look how clean the filters are. I did not touch them so it leads me to believe that unit is pretty well protected. It's not perfect, but it does its job.



Not to jack the thread, but in the last photo, you'll see my CB antenna cable passing by. I have been having a lot of alternator whine in the CB and I wonder if the cable being in the proximity of the pump is helping to induce this noise...

 

[WCPoe]

Install complete but I have a leak at the tank somewhere

Well, I completed the installation but I have a leak at the tank fittings. I had some trouble with the disconnect on the fuel supply but had a pair of curved needle nose pliers and finally managed to press the quick release in far enough to get it to let go. I left a small blue clip on the elbow which I also took off because the new disconnect had one. It's dripping from that general area and I got frustrated and just parked it outside on the gravel area so it wouldn't leak all over the shop.

The new quick connect went on easily and clipped in place, I could see it seat all the way but I'm wondering if damaged the elbow somehow. The new FASS holds 16 psi and is real quiet so I'm happy with that but now I think I'll have to pull the bed off and see where the fuel is leaking from.

Just my luck!!! :{