Archived FASS DDRP 02 Installation Problems

[AH64ID]

I do know that for some reason the VP does not like high inlet fuel pressure during startup. Don't know why, it just doesn't. Key on, fuel pump primes system for 1 second, then nothing until the engine starts.

My guess is that the DDRP creates pressure much faster and if you crank in that 1 second you are trying to start with too much fuel pressure.



If you wait a second or so after you turn the key to run I bet it starts every time.

 

[fstfish66]

great reading on this topic, a few questions on both lift pumps,,



i have an 02 auto 4x4 99 thousand miles,, orignal factory lift pump went around 63000,,,with replacement orignal style, i have 12 / 13 psi at idle,,and 5 at WOT,, im researching this FASS DDRP 02 replacement pump, and found in fo thur google, on a differnt truck site, that the recently built fass pumps 2009 was the posting date,,the electric motor pf these pumps are failing at a high rate,,,,



what are we seeing from guys on this site ????



im currently wanting to replace the current pump orignal type but 2nd one since new 1st replaced,,, with some thing stock,,my truck has no mods or horse power up grades,,,



what was the easyest way to install the relocation kit ?? how did you cut the steel line??? remove the tank ??? any info would be very helpful,,,,thanks in advance,,,

 

[MAYoung]

See my comments above. The FASS DDRP is designed to be a bolt on replacement. I am not familiar with the 2002 model truck but I did not have to cut the metal fuel line. The line turns to plastic/rubber about 20" before the pump on the 1998. 5 model so I placed the inline filter in that spot. The rest requires a mild amount of mechanical ability but most of the effort involved the discomfort of reaching into the spot for mounting the unit and getting the bolts washers fitted and aligned.



I have not seen a great deal of comments of failures for the FASS DDRP on this site although it does carry a 4 year warranty on the unit itself (assuming that the pump was purchased from a FASS authorized dealer). Like all things mechanical/electrical, I assume that it will one day fail. I plan to carry an old style Carter pump and the old plumbing with banjo washers with the truck so that I can revert back to a spare pump in the event of a field failure--total cost of spare unit and washers was about $135. 00. It is simply a question of how mission critical your truck will be when the pump fails.



M. Young

 

[fstfish66]

if i go wit hthe fass DDRP 02 i will relocate it to the frame closer to the tank,,and probably put a filter inline before the fass pump,,



on the other sites i found thru google, they talk about the fass living longer using a bigger fuel line, they say the factory line is to small in I,D. so i was under looking at what type of quick disconnect the fuel line to tank fitting is,,and i can see the pick up tube size is just as small,,so a bigger feeed line the the fass or any other pump doesnt make sense, the pick up pipe into the tank would have to be replaced to make that thinking be effective,, im now wondering if i should just move the factory carter pump closer to the tank,?? use a fass?? or the other brand of pump raptor 150 i think has an adjustable pressure built in,,i just looked at my current pump it has 30 000 miles on it in 4 years,,,



MAYoung how long have you had the fass ??? and what type of inline filter did you install before the pump ?? im thinking a screw on type like an auto filter,,

 

[MAYoung]

Reply to fstfish66:



I have only had the DDRP 02 unit installed since February 4, 2011. Read the comments posted above.



It is my understanding that when these lift pump problems developed, people began to move the pump closer to the fuel tank. Many indicate through their postings that they obtained better fuel pressures and longer pump life. Many of the aftermarket units do offer a "remote" installation. I have read about the need for larger diameter fuel lines but many of these needs involve huge boosts in horsepower and and other tricks performed on the engine. Some readers have had starting problems when they sent too much fuel to a stock injector/fuel system.



I do recommend spending a good hour on a search in this forum for your needs. Many of your indicated interests have been performed by others far more knowledgeable than I. I takes patience to sort through all the posting but eventually a clear picture emerges as to what individuals have experimented with and the success that they have experienced. Good luck.



Regards,



M. Young



P. S. I just installed a simple inline fuel filter as provided by FASS. There are much more elaborate filtering system but they involve a remote mounting. Again, do a quick search on lift pumps within this site and the whole screen will lightup. You will have all the information you need and then some.

 

[fstfish66]

mick,,thanks, im going to price a new carter lift pump and if they still carry it relocate it with a pre filter,,,,and carry spare for now,,,ive only put 30 000 on it in 4 years working ok for now thanks for your replys,,,

 

[ioli]

Hi All,

Quick history. Bought my 2001. 5 HO 2500 4x4 July 2001. Love my truck and it has 119,120 miles on it today. It is stock except for 4" exhaust from turbo back with BANKS 4" down elbow tube where exhaust pipe mounts. Exhaust break with big head waste gate acturator not installed yet. Oil & filter changes every 3,500 miles and greased. Air filter changes every 10,000miles. Fuel filter changes every 5,000 miles. Coolant changed out every 36 months with distilled water. All filters are FLEET GUARD purchased from GENOS GARAGE. Love those guys. Front end, NV5600 transmission, Transfer case, and rear end fluids changed out every 50,000miles with REDLINE PRODUCTS. Front brake pads changed out at 112,000miles. I work and play in Macamaya mountains so I don't have much room for procrastinating on PM. I am a Geothermal/Hydro ELECTRICAL POWER GENERATION SENIOR OPERATOR by trade. On off days I hual sand, rock, cinder blocks, manuer in my 6' x 12' BIG TEX dump trailer for $. I live at an elevation of 1300 feet. Power plants and Control center location elevations are 1600 feet to 4950 feet so things change in my driving conditions every day. I love these Dodge cummins so much I bought my wife an 2005. 5 DRW HO Dodge cummins so she can take her horses where she wants, haul hay, Lance camper etc, and give me my truck back. She wouldn't let my truck go after she used it, to go to Santa Rosa shopping. She loves her 05 truck and I service that one as I do mine.

My truck has been trouble free all this time except the for hydraulic clutch actuation device linkage failed @ 116,000miles, purchased and installed SOUTHBEND'S system, and on my way again, no problem. Sunday 7/10/11 I performed fuel filter change. Went through normal priming of 8 to 10 cycles no starts. I could hear the carter lift pump run its cycle each time. Then I fired 'er up and she started & ran as usual for approximately 1. 5 minutes. Then stopped as if I turned the key off. #@$%!> OK knowing the carter lift pump issues from reading these forms since 2001 I loosened ejector lines and then repeat prime cycles. Nothing. #@$%!> OK then I remove filter canister lid and filter. The canister is empty except for 1/4" level of fuel in it. Asked my son to hit the ingnition for a lift pump cycle, and it ran its cycle as I visually watched to see if any fuel would flow into the filter canister. Nothing coming into the filter canister. #@$%! For the last two years I have topped my fuel tank off keeping it full to 3/4 all the time knowing about the carter lift pump issues. At this time my fuel tank is approximately 45% full. My trip meter has 275miles, I reset it at every fuel up. So I know I have fuel, but this is the first time I have let it get this low in two to three years. I don't thing my fuel tank pick up screen is clogged or plugged. I checked for codes and got these: P1693 & P0230. I have been looking for what these DTCs mean but haven't found them yet. If you all know what they are please reply with that info. I hope it is not my VP44 wiped out. I am going to Boy Scout camp with my sons troop up in the mountains for a week on Sunday and this would be a bummer if my VP44 is failed. If it is failed I will be pulling the VP44 and will ship it to BLUECHIP for the rebuild work, I know they are higher $ but I believe they have the right mind frame on what these VP44's are all about. I will also be replacing my ejectors as well and thinking of DDPs in stock application. TDR's recent article on them was great. But I will have wife's 05, and she will have the T-BIRD for a week. I orded a FASS DDRP from Genos Tuesday, overnight air shipped it from Georgia and it arrived here at my home in HVL yesterday at 5:00pm. I have been reading MAYoung's forms and info on this install from January/February 2011. I pulled out the old carter lift pump yesterday, via removing fuel filter canister assembly yesterday. Was fairly quick 25 minute task. When reading DDRP install instructions can see some changes from Carter pump as MAYoung has posted. OK> I do not have a fuel pressure guage set up. I know that is my bad! That is the one thing I have procrastinated about. I will begin the task of install now. Will post on progress. Take care.

 

[ioli]

UPDATE ON FASS DDRP INSTALL IN STOCK LOCATION INFO: My last post was a bit lengthy "sorry". I have the in line prefiliter installed. Kinda straight forward, but I would prefer to have it further back closer to the fuel tank, but it will work for now. I checked for codes and got these: P1693 & P0230. I have been looking for what these DTCs mean but haven't found them yet. If you all know what they are please reply with that info. Thanks

 

[Gonzo 1066]

How did you figure out that 13psi was not enough pressure at WOT?? The stock carters often drop down in the low single digits. It is COMMON to see 3-5 psi at WOT with the stock pump and the engine keeps running at that pressure. I think you are under the mistaken assumption that more pressure equals better performance.

 

[Sticks]

Pressure does not equate to performance, it is a safety buffer for the VP. I personally prefer to keep her in the green, not dark orange.

Some trucks can run with low supply pressure, and are still running. It is also the number one cause of failure for the VP, especially on trucks performance tweaked above stock levels.

 

[pfmoale]

Thank you to all that have posted information here.

I just purchased a DDRP, and am getting ready to do the installation. After reading over the instructions, one item is confusing to me. Item #7 in instructions says :
"Using the 10 X 32 tapered flathead cap screw, locate the mounting hole of the support arm round this bolt while threading".
This screw looks to be the same as the 3 small screws that hold the aluminum mounting plate to the pump. These are what's called button head cap screws.
What exactly do they mean by this ???

On another item, why do they put a very fine mesh screen on the bottom on the fuel pick up / sending unit. This is the HARDEST place to change / service a filter !!!
I dropped the tank once before thinking I had plugged the filter mesh screen, and ended up damaging it, so had to buy another one from Dodge. Is it absolutely necessary to have that one there when you can put one just outside the tank ?
I would like to get a more detailed response from a Dodge engineer than just "No".

To the fellow who asked about what trouble codes mean. Chip Fisher from Bluechip Diesel says the P0216 code is the "VP44 death code". Go to Google, put in P_ _ _ _ code for 5. 9L Cummins engines. You'll get a lot of information.

Any and all help to my (screw) question is greatly appreciated.

Regards,

Peter

 

[ioli]

Peter,
On Thursday I completed my DDRP install. After a few cycles for fuel system purge the cummins fired up and is running extremely great. The cummins has improved performance. I think the carter has been weak for a while. I kept it and I will dissasemble it and see what its all about. I had the P0230 DTC code failed primary fuel pump. I suspect when I checked for DTCs with the carter pulled, the ECM wigged out seeing a power failure fault with the carter pump not plugged in. Engine check light was on but after 5 start/runs engine check light is no longer on.

The three mounting bolts didn't come with my pump. I called Genos and they are sending me the bolts. I used my tap and die set to find the bolt size as (5/6"-18 X 3/4"). I went down to local hardware store bought three stainless bolts, flat washers, and lock washers and used them to mount the DDRP.

The 10-32 screw wouldn't work for me. The hole in the mounting bracket is bigger than the screw head, at least the screw in my kit was that way. I couldn't get the mounting bracket to line up to engine/pump mount as it did with the carter pump. I just rotated it straight up out of the way for now. I swapped the fuel supply line and fuel return line in the frame hold down to keep the inline pre-filter from rubbing on the frame.

Hope this helps. Got to go.

Regards Vince.

 

[dkoldno7]

ddrp

Hello,I've had a ddrp on the frame mounted on my 2002 for about 30,000 miles,puts out 17,15 psi. seems to work fine. just my 2cents.

dkoldno7

 

[MGault]

I understand the VP sends on average 70% supplied fuel back down the return line to the tank. All that extra fuel is used for cooling the pump.

Question. What pre-injector pump pressures can we expect to see at full throttle with the DDRP on a stock motor? I have the original lift pump, an i see 12psi at idle and down to 7-8psi at full throttle with stock except #9 smarty.

 

[pfmoale]

My DDRP, on a 2001

All,

Good info from everyone.



I installed one recently. Put it next to the engine, as pig tail electric line is just long enough for it there.



I also have an LED light mounted in center gauge pod, PLUS an electronic fuel gauge 0 to 30 PSI.

Recently, towing our 7,000 lb TT, I opened her up and pressure dropped down to 8 to 9 PSI, and the LED light just started to flicker. It's set up with the 5 PSI pressure switch. Why in the heck is it starting to flicker when elect fuel gauge is reading 8 to 9 PSI ???



Brandon @ Genos garage said to double check by temporally installing a manual / mechanical pressure gauge, and tape it to window.

Still need to do that. FF was recently changed, so it has very few miles on it.



I would like to see NO LESS than 10 PSI @ WOT, to be on the safe side.

Has anyone gotten the P0216 code from their scanner ?

2 other things. Every once in a while, fuel tank gauge will go to empty, little "low fuel light" comes on and dings, then about 10 to 15 seconds goes back to normal. (stupid electronics !)



Again, every once in a while, I get a "No response" from the pedal, then it will reset itself again. (did I mention stupid electronics !)



Has anyone installed the DDRP electrical extension wire to mount LP back on to frame, without cutting the OEM connectors ? At $17. 00, keeps things original.



Thanks for any info.



Peter

 

[Sticks]

All,

Good info from everyone.



I installed one recently. Put it next to the engine, as pig tail electric line is just long enough for it there.



I also have an LED light mounted in center gauge pod, PLUS an electronic fuel gauge 0 to 30 PSI.

Recently, towing our 7,000 lb TT, I opened her up and pressure dropped down to 8 to 9 PSI, and the LED light just started to flicker. It's set up with the 5 PSI pressure switch. Why in the heck is it starting to flicker when elect fuel gauge is reading 8 to 9 PSI ???

most sensors are not exact. 5-10 psi may be the range that it operates.

Brandon @ Genos garage said to double check by temporally installing a manual / mechanical pressure gauge, and tape it to window.

Still need to do that. FF was recently changed, so it has very few miles on it.



I would like to see NO LESS than 10 PSI @ WOT, to be on the safe side.

Has anyone gotten the P0216 code from their scanner ?

Hundreds of times at work, 3 on my truck. Not a death code if fuel pressure is below 10, but something to worry about if fuel pressure is good.

2 other things. Every once in a while, fuel tank gauge will go to empty, little "low fuel light" comes on and dings, then about 10 to 15 seconds goes back to normal. (stupid electronics !)

Known Dodge fuel sending unit issue - unreliable

Again, every once in a while, I get a "No response" from the pedal, then it will reset itself again. (did I mention stupid electronics !)

TPS / APPS on it's way out. Rarely sets a code until it is completely dead.

Has anyone installed the DDRP electrical extension wire to mount LP back on to frame, without cutting the OEM connectors ? At $17. 00, keeps things original.

Always.

Thanks for any info.



Peter

 

[MGault]

That dead pedal could be your TPS. My pedal would randomly have no response till it was tapped with my foot 2-3 times. Drove it like that for a year till it grew too often. $180tps from genos fixed my 99 dodge.

Seems like this DDRP gets people like me all excited about not having to spend $450 on a larger unit but dont have to install the original pump. I havnt seen much as far as performance gains over original. Maybe just longevity. -mike

 

[Sticks]

You don't get performance gains from a transfer pump. You get the longevity and longer survival rate for the flaky VP44.