Engine/Transmission (1998.5 - 2002) FASS & in tank lift pump causing cavation??

[TSkeen]

Installed gauge and noticed pressure was way low. My VP 44 is only about 3 weeks old & wanted it to last awhile. So ,installed a FASS 95. Great pressure. Drove the 100 miles or so home from the shop that performed the work feeling like I had made a wise decision. Next morning,truck started as usual but died after about 1 mile and would not crank. Felt & sounded like it ran out of fuel. Called the shop that performed the install. He had me check for codes on dash- there were none. Being 2 hours away,He suggested I tow truck to local diesel shop that he has good relationship with. About 1 hour later they said VP 44 had died... . again. Suggested since dodge dealer had , only 3 weeks before, replaced the pump we tow it to them. I did . Next day, they phone me and proclaim truck fixed. . system was full of air. Here is where it gets funny... . I show up to pick up truck and am thrilled that there was no charge ... I have spent lotts of money there . Felt lucky it wasnt pump. Usually a car hop finds the truck on lot and delivers to customer waiting area. After waiting unusually long , I walk back through service area to back lot and discover truck with hood up and service mgr hitting starter hard with no results, turning over well but refusing to start. He calls over the diesel tech that bled the system earlier. He begains same routine that worked before, this time no results. He said truck was full of air before... removed air re-gained prime and fired right up... ... NOT THIS TIME... . His opiouin ,was the problem was in the new fuel system. Crank ,crank, crank no start . Didnt seem to have air in line as before. This was wed before thanksgiving about 5;30 and I knew I wouldnt have truck back before monday. Service MGR looks truck over and allong with tech and without really saying it,condem the FASS system as junk and the root of my problem. Them knowing I have a new 06 CTD,they say "lets wait till monday, speak with the shop who installed the FASS decide then what to do. "There thinking was it should be towed back to them. I leave ,confussed and a little angry knowing i had allready spent $$ for two tows and now looking at another 100 mile tow. BUMMER . . ALL I WANTED TO DO WAS PROLONG THE LIFE OF MY THIRD PUMP. This truck has 240,000 miles & had never left me stranded before. Limpped home ,yes ,but never died. On my way home trying to solve this problem in my head, I remember the headlights flashing while the service MGR had grinded away on my poor starter. A LIGHT WENT OFF IN MY HEAD... . COULD I BE LUCKY... . I turned arround and went straight back to dealer... the service tech that I deal with was still there. I asked for key to truck pretending to need something out of cab... Knowing that if my hunch was right ... . the truck would start right up. COULD I BE SO LUCKY??? Sure enough,I cylcled the key in door making sure to bump all the way left then right. Put the key in the ignition Let the wait to start light go off and SHE STARTED RIGHT Up... WELL even a blind squirell finds a nut ever once in a while. My hunch was right ... The car hop, not having my key FOB , had used key to un-lock door and didnt cycle the key through its complete rotation causing the truck to start at first then go into thieft mode AND NOT START..... I drove the truck home and shes still running. I for got to mention that when truck first failed to start the fuel gauge read just over 1/4 tank Before having he towed I added 10 gallons of fuel but she still failed to start. After searching many threads I believe The in-tank system needs to be re-moved or at least modified in order to have full use of my 30-plus gallon tank . How low do you think I can run tank the way she is now & not loose prime?Am I on the right track???02 2500 4x4 240,000 miles sory so long.