Archived fuel pump? Truck will not start.

[raxley]

I sure had a heck of amount of grit in my prefilter/heater. I also noticed the identical colored dust, black, that was oozing out of the filter that I changed a couple of weeks ago. As soon as I get a chance, maybe before I get my fuel line, I'm going to drop the tank and check that filter there, and also replace the hoses. I ordered a OFV yesterday too.

 

[GAmes]

I'm going to drop the tank and check that filter there..........

There isn't a filter in the tank, but there is a basket that looks like a screen. It is there to hold fuel for the pickup tube when the fuel level in the tank gets low.

 

[crabman]

Here is the link to Joe G's write up. It is a excellent write up.
http://www.cumminsforum.com/forum/94-98-engine/58777-joe-gs-fuel-system-writeup.html
I have bookmarked it and printed out a copy to keep on file.

 

[raxley]

Well, finally got it running again. I kept the old line with the bango fitting, and drilled out the hollow 5/16 nut that goes into the fuel prefilter/heater for a 5/16" brake line. I put the 5/16" brake line into the lift pump intake (I cut off the prefilter and kept the 'spacer'). I had ruined the line coming into the prefilter by not being able to see down there (impatience played a part too). I twisted the metal fuel line by unscrewing it without taking the line out first. So now the fuel goes straight into the lift pump, and there is no prefilter/heater anymore. I need to drop the fuel tank and check it out for that black grit. For the solenoid (the real problem) I put a wire with a spring on the linkage for the solenoid, and I have to open the hood to turn it off. I'll probably get a cable turn off thing if I can't repair the broken solenoid, I don't want to spend the money right now (and I like the idea of something that can't break)
Much thanks to everybody, it would have been much harder (still might not have figured it out on my own) without the TDR's help in the 911 forum
That is also at good article-Joe G's writeup on the fuel system.
I ordered the OFV, and I'll try the vise grip trick tomorrow. BigPapa-glad you told me to stay away from the adjustable one, I would have spent ~$60 otherwise, I got the stock one for $27.

 

[BigPapa]

Have you checked the key on the shaft? There's something else wrong if your plunger fell out of your solenoid.

 

[raxley]

That 'plunger' actually went to the solenoid. I took it out from above. I can't see anything from above, but still I would try. That's also why I broke that line (not seeing well) I removed part of the lift pump without taking the line off first. I thought that it WAS the line. I could feel the spring of the line as I turned it, but I thought if it is stuck, then it will have to be broken anyway. If I had looked closer, I would have seen that the actual line had a nut in the center of the part of lift pump that needed to be loosened.
After I pulled the lift pump, I got out from under the truck. I was trying unsuccessfully to see down from above, when I noticed the solenoid piston (what I later took to be the plunger) I took it out and assumed that it went to the fuel pump. The solenoid, at this point was nowhere on my mind.
Funny thing is, I almost got the 'plunger' into the lift pump hole. I put it in at a downward 45 degree angle, but it protruded a little bit. I knew that the (real) plunger on the lift pump would be compressed while tightening the nuts, but this was too much. I also could not get the spring on the 'plunger' either. So I got on the TDR and asked you how to get this darned thing in, and you responded with the picture.
Kind of embarrassing. I was in a hurry and couldn't see well and assumed too darn much-I 'knew' what was the problem!

 

[BigPapa]

Don't be embarrassed. The best learned lessons are the ones we learn the hard way. Being in a hurry and not following tips from folks that have "been there, done that" are your worst enemies. Shake it off.

So, the solenoid fell apart when you removed it from the pump? In that case, clean the plunger, spring, and inside the solenoid good, put the plunger back on the shut off lever with the spring over it and replace the solenoid over the plunger. I would not use any kind of grease or lube. Mine has been assembled dry with no boot for many years and several hundred thousand miles. Give it a try. If it doesn't pull up or keep the lever up, throw it away. You've lost nothing. If it works, drive it. I suspect your deteriorating boot was your issue.