Engine/Transmission (1994 - 1998) Low power issue HELP

[RON'S RAM]

Any advice from experienced 2nd gen 12 valve owners would be greatly appreciated.

About a month ago, I noticed a drop in power and very low boost on the gauge. Normally I can easily get over 30 psi, but then had trouble reaching 8 psi. I removed the AFC housing and ran the truck without it to see if the power came back or not. No difference, no power & very little smoke. I pressurized the intercooler & hoses and found the intercooler leaking. I installed a new intercooler & hoses and can now get 10 PSI with 1100 deg. pre turbo. Still no where near where it should be. Tonight I noticed that on the BD brake controller there is a pin sticking out the side, which looks like a stop for full open. My linkage doesn't come near that stop. Is it possible that the exhaust brake is not opening completely? Would that cause low boost? I don't know much about diesels yet. If the waste gate wasn't working properly, would that cause low boost?

I pressurized the boost system again tonight & didn't find any more leaks. I may test the fuel pressure soon if I don't get any other advice.

Any ideas???

Thanks,

Ron

 

[TyThompson]

I would say that an exhaust brake that isn't fully opened would defienitely cause a decrease in power, but I would think you should be able to hear it, hear a difference in the sound of the exhaust.

Other than that, I would definitely check fuel pressure.

 

[FDavid]

Sometimes its as simple as a clogged fuel filter.

 

[RON'S RAM]

Thanks, I forgot to mention that I replaced the fuel filter, cleaned the pre filter, cleaned the air filter.

I don't see much info on here as far as fuel pressure gauges on the 12 valve engines. Is it worth it to install a permanent FP gauge? I was told that they always fluctuate due to the mechanical pump. Has anyone installed a gauge w/ 2 sending units, pre & post filter??

If so, where did you hook them up?

 

[Missouri Mule]

I believe on the 97 you can hook up fuel pressure guages to the the supply line to filter and the fuel supply line going to the injection pump(you should have to banjo fittings on top of fuel filter).



Do you have EGT guage? If you do what is it reading?

 

[RON'S RAM]

Last night, I moved the AFC housing full forward and now get black smoke before the turbo spools up and am now getting up to 11PSI boost at around 1100 Degrees pre turbo. Seems kinda hot for no load.

 

[hsmith]

With no boost and 1100 egt's, there has to be a leak in the air system. Are you sure things are good between the turbo and the cooler? That boot at the frame is a place where it rubs and causes a leak. Sometimes, like mine, it slips off a tad too at the cooler.

 

[RON'S RAM]

At 1100 deg. I had 11 PSI boost. The hoses & clamps along with the intercooler are brand new and the system has been pressure tested. I can't find any more leaks.

 

[Missouri Mule]

I take it you killed the cat. I check your exhust brake out again.

1100 is to hot for no load.

I think if your fuel pressure was low the egt's would also be low.

 

[RON'S RAM]

Power Loss Fixed

I take it you killed the cat. I check your exhust brake out again.

1100 is to hot for no load.

I think if your fuel pressure was low the egt's would also be low.

Problem Solved: Well even though the intercooler had a few small holes, that's not what was keeping the power & boost down & the temps up. The B&D exhaust brake was 70% closed. A retaining ring inside of the exhaust brake unit broke not allowing the linkage to move as it should. I was told that this has been a problem and it has been re-designed. The retaining ring is no longer available from B&D or anyone else that I spoke with. B&D would sell me a new brake canister instead, but I was able to repair it and enjoy that Cummins power again!! Oo. Thanks for everyone's input.

Ron