Engine/Transmission (1998.5 - 2002) fuel filter leak at heater wires

[RNixon]

My '99 Cummins is leaking fuel from the top of the fuel filter housing where the fuel heater wires go in. What's the best fix for this.



I found a message on the board where someone was quoted a price of $1,100 for a new housing. I wouldn't do that, but what is the best alternative. Someone mentioned sealing the wires with RTV silicone. Is that a workable fix?



My service manual shows a unit replacement of the fuel heater, complete with wires attached. Is that still available?

 

[Stanbery]

The RTV might work for a little bit, but i wouldn't trust it as a fix... Nothing from the stock filter housing is available anymore. They will try to sell you the replacement for $1100 or whatever the price may now be. Maybe you can find someone with a used one.

 

[hsmith]

Go with the Fass system. You can do away with the factory filter. Lot cheaper too.

 

[RNixon]

I've been looking at the FASS. Looks like a good product, but I don't quite understand how it would go in. Would I completely remove the stock lift pump and fuel filter system and plumb in the FASS directly to the VP44 injection pump?

Is there a replacement for the stock fuel heater in the filter housing?

How difficult is it to install the FASS? I'm a passable shade-tree mechanic, but this looks like a fairly major operation. Can someone estimate the time required to do this installation? My truck is unusable right now. Need to work out how to get along for long enough to get the job done.

 

[RNixon]

One more thing. With a FASS system, do I still need a fuel pressure gauge?

 

[cj hall]

fass it and forget it.

Hello RNixon



I put a fass on a 2001 it took around 5 hrs just for the fass we also plumbed it for heat and heated the tank also.



on that truck it does away with the stock filter and lift pump goes right to the vp44



we used an 95/95 unit but I would go with the 150/95 or the 150/150 unit

it has bigger filters then the 95/95 one



will be doing another 2001 in the next few months.



And yes get a fuel pressure gauge , this will give you an idea of whats going on.



hope this helps

cj hall

 

[RNixon]

Interesting. I wasn't thinking of the 150 unit for my stock truck. I checked a few web sites, and found a couple offering the 95 and 150 units for the same price. For same price, would there be any reason not to go ahead and get the 150 gph?

I apparently don't understand FASS product line. On one web site I see "95 series" with models FAS95/150-1008 and FAS95/95-1008. Then there is "150 Series" with models FAS 150/95-1008 and FAS150/150-1008

I found one explanation saying the 150 series is for industrial / high mileage use and has "industrial strength filters" vs "standard filters" on the 95 series. It looks to me like the 95 series would be right for my truck with no extra performance upgrades. Not sure what those "industrial strength" filters would be.

Looks like I need to call the FASS guys and talk about this with them.

5 hours installation doesn't sound too bad. I could probably do that.

 

[cj hall]

RNixon



The 95 series pump is the smaller unit and the 150 series pump is bigger.

I have a 150/150 on my 2004 it works great the only thing is that I am running vegetable oil fuel and the amps that I am pulling with the 150 is very high the 150/95 gph would be the fuel pump I would replace it with or at least change the gear to make it a 95 gph.



If you are running stock the the 95/95 would be just fine the only thing is the filters are harder to find on the road and the water filter is only made for fass pumps you can run a different filter but you will need to mod the pump not hard to do but its more work.



bigger filters last longer and they are lots of other makers for the filters on the 150s. I have been back flushing the water filter and this has cut down on the cost for the filters you might look in to doing the same with the small one also but it will depend on what is in side of them.



diesel dan is the one you need to talk to about the best one for your truck.



if you want you can heat the fass unit base with water from the engine it works great then you need a fuel temp gauge also.



good luck you will be happy with the fass pump system



cj hall

 

[RNixon]

I'll plan to talk with Diesel Dan tomorrow. Hopefully this will not be too hard.

 

[RNixon]

I'm planning to call Diesel Performance Products today about a FASS for my truck. Does anyone have any suggestions for questions I need to ask them?

 

[Batphreak]

Mine had that leak. I goobed it with silicon ended up running that way for about a year. Then I bought a used 2000+ fuel filter housing plus the lines that connect it from a board member. It bolted right in place, I had to make a couple pigtails to adapt the heater and WIF connectors. That gives me basically the same thing Dodge and Cummins charge $1000+ for. FASS or Airdog is a very good solution as well.

 

[RNixon]

I decided to go ahead with the FASS. It is due to be delivered from Geno's right about now.

My local mechanic did some checking, and we verified that Dodge has a "Fuel Separator Kit" Part # 5011618AB that replaces the original filter housing for a price of $1135. Stunning! I haven't seen the thing, but for that price, it should be gold plated. Also confirmed that Dodge has a replacement kit for the bad lift pumps (Part # 68003854AA for $524 (parts only). This is the new design that puts the pump inside the fuel tank. So for only around $2,000 or so I could get the bad design items fixed. I decided to pass on that.

I'm a little worried about the difficulty of installing the FASS, working in the driveway, without a lift. I've done bigger jobs, but not in a long time. Will no doubt be interesting. My regular mechanic (not a diesel guy) declined to do an installation of 3rd party parts. I can understand his reluctance to install something he has no knowledge of.

I sure would like to find a good Cummins mechanic out here in Northwest Harris County (outside Houston). If anyone knows one, please let me know

 

[RNixon]

FASS received Friday afternoon . . . Installed Saturday . . . Problem solved.

I love it when a plan comes together!!

My truck is back in action! It took all day to install the FASS (I am definitely too old for this s#*&), but once done, it came right up and works like a champ. This puppy pumps a LOT of fuel. I purged the system by pumping into a small bucket. The pump ran for about 30 seconds and almost overflowed the bucket. About a gallon or so in 30 seconds. That should be enough.

It took a lot of cranking to get the engine to start the first time, but once it kicked off, it was back to normal. Starts almost instantly now, just like always.

Thanks to Diesel-Dan at Diesel Performance for his advice. Thanks also to Andy at Geno's Garage for shipping the FASS the same day I ordered it. And thanks also to all who offered good advice. This group is great!