Engine/Transmission (1994 - 1998) hard starting problems fixed

[darom]

I had the same problems like many of you: long cranks, flooring gas pedal, idle stumbling etc. Finally ordered some new marine type grade fuel hoses, new starter contacts from Larry Buck, and fuel preheater kit and molded hose (between fuel preheater and lifter pump) from the local Cummins dealer. I also replaced the overflow valve with a new unit.



In the picture you will see the ruptured hose. The cut was underneath, so it was visible only looking from the starter side.



The truck starts right away like it used to. I can't believe I made it from Sacramento to Bakersfield driving with such air/fuel leak.



Overall job took me about 6 hours. I had to use a floor jack, 10 mm wrench and 2x4 to unbolt the most stubborn starter bolt.



Thanks to all of you who posted the guidelines and how-to's articles on this annoying problem. This is one of the best boards I subscribed to.



Regards!

Denis

 

[wcjp]

Looks worse than the one that was causing my problems on my 96'. Congrats on finding the problem.

 

[Coalsmoke]

I have the same problems, could you please tell me where abouts on the truck I find this little hose at and what do I call it if I need to get a new one ordered? Thanks

 

[Joe G.]

There are several things that can cause an air leak. Just swapping parts because someone else had a particular problem may just be an exercise in frustration. If you would like a write up I made for another forum on how the supply fuel system works, what can go wrong, and how to fix it e-mail me at -- email address removed -- . In the mean time the most likely problem to cause hard starting is a bad fuel hose between the steel line from the tank and the steel line for the fuel heater/pre-filter assembly. The fitting on top of that assembly can leak hear if the crummy little composition washer is bad. The fuel heater can leak air. The hose that failed in this instance can leak air. You also can have an air leak at the fuel tank module.

 

[Coalsmoke]

There are several things that can cause an air leak. Just swapping parts because someone else had a particular problem may just be an exercise in frustration. If you would like a write up I made for another forum on how the supply fuel system works, what can go wrong, and how to fix it e-mail me at -- email address removed -- . In the mean time the most likely problem to cause hard starting is a bad fuel hose between the steel line from the tank and the steel line for the fuel heater/pre-filter assembly. The fitting on top of that assembly can leak hear if the crummy little composition washer is bad. The fuel heater can leak air. The hose that failed in this instance can leak air. You also can have an air leak at the fuel tank module.

Joe, I really appreciate that. I have an e-mail on the way, thank you.

 

[Coalsmoke]

Joe, I really appreciate that. I have an e-mail on the way, thank you.

email troubles, I'll send you one later tonight when I get this figured out

 

[MacMc]

I E-mailed, too. I started having starting problems two weeks ago and I assumed the batteries were weakening. I just put in two brand new Optima Blue Tops (750 CCA each) and it didn't seem to help. It still starts slowly and weakly.