Help with mystery... truck just dies..

[BushWakr - RIP]

Ok guys, here's one for you. Some urgency here, he's trying to get away on holidays by Sunday coming.

My brother has a 92 CTD 5spd, 180 Inj's, pump mildly tuned.

He has replaced the lift pump 2 times, replaced the fuel sender/pick-up in tank, stock fuel filter, racor filter, checked and replaced fuel solenoid and still this thing will just up and die on him.

He drives along fine, and intermittently, when he applies throttle the thing just quits. If he's moving fast enough it will occasionally restart itself. There are no misses while running and he gets good mileage.

Also on occasion he will have to crank it 4 or 5 times to get it to start.

Each time he has replaced a part eg:lift pump, the problem seems to go away for a while.

Also seems that it happens most often at around a 1/2 tank of fuel remaining. (coincidence??)

He runs clean fuel, never see's water contam. and uses SPF every tank.

What in the 'wide world of sports' is happening here????



Any help greatly appreciated.



Thanks, Bob.

 

[JHansen]

Seeing as you guys have tackled almost everything fuel-related, I'd start looking at the electrical side. 1st gens don't have the most reliable electrical system in the world -quite possibly a connection powering the shutoff solenoid is loose? Maybe in the bulkhead connector-although I think the newer 1st gens are tons better than the older ones..... ignition switch and/or connector? Just tossing a few ideas out to you hoping that one of 'em sticks.....



Jason

 

[KEENO]

Hey Bush!



My thoughts are paralleling those of JHansen!



The (3) electrical connectors to the pump loosen up over time & loose contact.



My truck would be sailing down the interstate and then just quit... . and then catch again when contact was resumed. I replaced all 3 connectors a few weeks ago and haven't had a starting or running problem since.



It took about 10 minutes to do the three connectors w/ terminals from a terminal kit & crimper.



They're on there secure now.



KEENO

 

[nascar mark]

Have him try the on board diagnostic system. See if a code comes up when he turns the key... on,off,on,off,on within 5 seconds. Look at the check engine lamp for a flashing code. All codes are displayed as a 2 digit number, with a 4 sec. pause between codes.



Worth a try!

mark

 

[AMikonis]

Yep, mine did this, too. I aborted a parts run to KC because it was cutting out and restarting 100 miles from home. The D250 was new to me at the time and it really freaked me out because the W250 had never missed a beat. Course it hasn't done it since (I did tighten up the connections. )



You could carry a test lite with you, and if it starts cranking over and not firing, you can touch it on the post of the fuel solenoid and see if you have power with the key on. If not, then wiggle the blue wire and see if it comes back.

 

[mblair]

cutting out

mine was cutting out, and a post got suggestion of check solenoid connection on pump. With it idling, i could wiggle the wire and make it cut out. I took connectors off, sprayed brake parts cleaner on terminal fittings and crimped terminal a bit. That was about 3 or 4 months ago and it hasn't missed a beat since. It was a whole lot less than changing the lift pump iI thought might be the problem.

Good Luck. Max