Engine/Transmission (1994 - 1998) fuel heater burned

[Nate Skate]

started truck this morning to warm up, came back out and it had died. :--) I tried to restart and she sputtered and died again. Noticed some smoke coming from fuel heater. Wouldnt start after that. Researched and found bigramguy had similar problem, deduced it was probably the heater but didnt write back when finished with fix. Dealer want $240 for new heater. Would cummins have this cheaper ? If so how do I find nearest cummins dealer? Any one else have this problem?

Thanx for help

Nate

 

[Blackcloud]

Nate- All the parts in the fuel prefilter/heater assembly are available thru a Cummins repair shop,or you can buy the entire assembly. The fuel thermostat w/short wiring harness is P/N 3843722-S the heater element is P/N 3907766-S. Whatever parts you decide to get,they're gonna be much cheaper at Cummins than a dealer.

 

[Deezul1]

Look in the Yellow pages under truck repairs for Big truck shops. There might be a Cummins dealer among them and if not one of them will know the closest place.

 

[Josparkz]

try this :



http://www.cummins.com/service_locator/index.cfm

 

[JohnE]

http://www.cummins.com/na/pages/en/distributors/distributor.cfm?state=KY



Cummins Cumberland in Louisville



I knew there had to be a Cummins shop in either Cinci, Lex or Lou

 

[Bigramguy]

Sorry I didn't reply earlier,just noticed this now. I hope you got my e-mail.



I had a similar problem,and when it fried,it burnt a hole through the end of the heater right where it plugs in to the harness. Took me (and a few helpful folks on the TDR),a bit to find it. I Cleaned everthing off with brake cleaner,filled the plug cavity with silicone,and jammed the plug back in with the harness cut off,and all has been fine ever since. I was going to replace everything,when I found the time,but the truck runs just fine,even in extreme cold weather. I just double up on fuel conditioner when it's really cold.



I don't know if yours burnt up in the same spot,but it's worth a shot,at least to get it mobile again,or until you get the parts.



When I did look into all the parts,Cummins had them all,much cheaper than Dodge,just don't have the prices handy. Might as well do the pre-filter and o-rings while your in there.

 

[illflem]

I echo Chris' opinion, if it doesn't get below -30° you don't need the heater, your truck will run the same without it.

 

[Nate Skate]

Fuel problems

I filled the burned wire socket with epoxy and no go. There is no pressure when I prime with the manual prime button. (I used to hear fuel squirting when I reached prime pumping the button) So I ordered and replaced entire fuel heater, harness, prepump filter. This was entire unit. Cummins told me it all came together and I couldnt order seperate parts. $170 plus shipping. Still wont start and still no resistence when I prime with prime button. (no squirting sound) What should I do next? Could the lift pump be out or is there possibly a leak somewhere else thats allowing air into the line? Help please!!!

 

[Bigramguy]

I know when mine went,it took a lot of pumping to get it to prime. If it's been sitting for a while then all the fuel may have run back through the line to the tank,and it will not prime with the primer bulb. Once you get some fuel too the primer it may just prime easier. Another possibility is that you primer pump is no good,and that's why it won't pump.



A quick way is to add a little pressurized air to the tank. A rag and an air hose in the filler neck will work to help push fuel up to the pump.



Open the bleed screw on the fuel filter housing,and either do the air nozzle in the tank,or keep pushing the primer bulb until you see clear fuel (no more bubbling),at the bleed screw. Tighten the bleed screw back up. Then crack the line at the injection pump and do the same thing. It now should light up. It may run a little rough,or stall,but you should be able to get it going.



If your really stuck you could use a hand held vacuum pump to actually suck fuel up to the pump to help get it primed. Most parts stores sell them pretty cheap.



You could also jack the back end of the truck way up in the air,and let gravity help too.



If all else fails,e-mail me -- email address removed -- ,and i'll give you my cell #. Maybe I can walk you through it on the phone.

 

[Blackcloud]

Has your fuel return line been repaced?If not,what condition is it in?This is a known headache on our trucks... check yours. It is a real pain to replace,but it does solve some hard starting problems.

 

[Nate Skate]

Thanx for all the help. Bigramguy, you were right. I put air to the tank and forced fuel through the line. SHe started right up. I wonder if I needed the new part? it may not have started after I epoxied it because of the fuel running back to the tank. It all makes sense now. Apparently, the air leak allowed the fuel to completley empty back into the tank. Thanx again for all the help.

Nate

ps. I opened the old pre strainer and it had a bunch of gunk in it. It smelled like epoxy. You might check yours just in case some silicone was pushed into the strainer.

 

[Bigramguy]

Glad to hear you got it going,mine was a PITA too.



Thanks for the heads up on the fuel strainer,I will check it out,it's time for a bath anyways



You may or may not have needed the part,but at least now it's running and you know it's fixed right.

 

[Cooker]

Your lift pump may still be bad. If the system is kept primed, like yours is now, the injection pump can pull enough fuel to keep the truck running.



bighammer just expereinced this problem. After a fuel filter change (and breaking the primed fuel system in the truck) the truck would not reprime with the primer button (no pressure at the button). After a few phone calls he decided the lift pump died. A new lift pump, primer button had pressure, and problem solved.



Just an FYI.

 

[Nate Skate]

Doesnt the lift pump slowly go out. Losing power gradually? I seem to have plenty of power.

 

[Bigramguy]

If you have plenty of power,you should be fine.

 

[Cooker]

I am going to disagree with Bigramguy a little here.



The truck still can have decent power with a bad lift pump. bighammer didn't mention anything about a decrease in power and there have been several members who have had bad lift pumps which only cause loss of prime issues and without low power situations.



Nate, I am not trying to worry you and if you truck is running fine I don't know if I would worry too much right now, especially if your truck is starting fine. Just keep this in mind the next time you change your fuel filter.

 

[Bigramguy]

Cooker



This loss of prime issue,is it just that,loss of prime ? or failure to prime after the system has been opened ? Was there any noted pressure loss when running ? I'm just curious,as I have had a few where the primer portion of the lift pump was a little screwy,but once running it ran fine,and no loss of pressure from the lift pump. Seems as if the little primer needs a bit of fuel in the system to get it working. Adding air pressure to the tank usually works. Any additonal info for future reference would be greatly appreciated.

 

[Cooker]

Loss of prime in bighammer's case was a failure to prime after the system has been opened. After trying everything he could think of (not wanting to throw a $150 part at the truck is didn't need) he finally decided to bite the bullet. Thankfully it solved his problem.



The other loss of prime scenarios I have heard about have been when the trucks sits for several hours, it has a heck of a time starting. After trying the usual items (changing fuel hoses, checking fuel heater for leaks, checking the overflow valve) the truck still loses prime. A new LP solved the problem.



Here is a link to a problem dieselnerd was having. I have read several other thread like his and LP was the culprit in those scenarios too.



https://www.turbodieselregister.com/forums/showthread.php?s=&threadid=39592



I don't doubt bighammers truck would have ran if he would have been able to prime the system. Evan Beck has reported changing many lift pumps at around 80k. He stated hard starting was one of the symptoms. Seems that the internal seals in the LP don't hold up too well.

 

[Bigramguy]

Thanks for the heads up,I have never come across that problem yet,but i'm sure i will one day. I guess I missed the discussion about it earlier.



I guess i've been lucky,mine just went over 350,000 the other day and no problemswith the lift pump yet. Knock on wood.



Only things i've done is the fuel heater repair,and a transmission line which wore through.

 

[illflem]

Seems like one of the first complaints when a lift pump starts going is hard to start when the truck is parked nose uphill.