Engine/Transmission (1994 - 1998) Lift pump replacement

[fulltimer]

I wanted to give back to the forum that has been so helpful by documenting my lift pump replacement.



I first detected a leak on the drivers side of the engine. I could not locate what was leaking. So I assumed it was the return hose. I bought the good hoses from JoeG and made the mistake of taking it to the dealer.



They could not find the leak and actually used my hose I gave them to replace the rubber part of the vacuum line from the pump to the wastegate#@$%!.



Last time I do that. So I cleaned the side of the motor and will fix myself.

 

[fulltimer]

Sorry I put the pictures in the wrong post.

I found that is was the lift pump leaaking. It is leaking from the priming button.

So after reading that I should not get a Made in China pump. I found a Carter on eBay
from Parts Boulevard. $184. 73 delivered.

As you can see from the photo Made in the USA.

 

[fulltimer]

I got the starter soleoid upgrade and another set of the good hoses from JoeG and will install these also.



I am also going to remove the fuel pre-heater.

 

[GAmes]

The o-ring on the pump is replaceable, but since you already bought the pump you have a couple options. Replace the o-ring and run the pump till it fails (another 100k or so) or replace it, replace the o-ring and carry the old one as a spare. If you don't want to hang on to the old one send me a PM, I'll be happy to pay pastage for it.

 

[fulltimer]

Worked on it today

I will post some more pics later. But for now here is picture of work area aftermath.



View attachment 72692

 

[fulltimer]

I took out the bleed bolt on the output banjo on top of the fuel filter bracket so I could drain the fuel from the filter.

I dropped this bolt and it disappeared. Does anyone know where I can get another one? Dodge says they do not have.

 

[fulltimer]

Modified starter also

I took the starter out as well as the boost tube and intake feed horn. Made it easier to get to the pump from top and bottom. Friend helped(he bought a boat he wants me to tow)



I got the LarryB starter solenoid rebuild kit. Here is a picture of the contacts.

View attachment 72693

 

[Grumpy John 4x4]

Carter

They Don't last very long, replaced mine with a Cummins' 108. 00 Del

 

[Grumpy John 4x4]

Starter

Did the same thing rebuilt the selenoid, but looking at the starter brush's were gone and the armature was not munch better, went on line at INDEX PAGE and got a brand new Densco starter selenoid Del for 260. 00! Dealer and Cummins wanted 715. 00 no wonder they are Bankrupt!

 

[Bob4x4]

I took out the bleed bolt on the output banjo on top of the fuel filter bracket so I could drain the fuel from the filter.



I dropped this bolt and it disappeared. Does anyone know where I can get another one? Dodge says they do not have.

Dodge doesn't service the small bolt by itself but a good counterman can find the complete bolt pkg.

 

[fulltimer]

We finished the job. we went at it from the top and the bottom. Took off the starter, air intake horn, and boost tube to get better access. Removed the fuel pre-heater while I had it off and replaced the screen. Only had a little bit of reddish lille bits in the screen.

The hardest part was getting the bolts started on the pump. I barred the engine over till the bolts could get close enough to start them.

Also replaced the hose from lift pump to pre-filter.
The stock hose was not a preform and was kinked. The new one I got from Dodge was preshapped.

 

[fulltimer]

picture

Picture looking toward pump with feed horn and boost tube removed.



Also new Carter pump was much bigger than the stock pump.



View attachment 72713