Engine/Transmission (1998.5 - 2002) My Lift Pump Saga

[bigdogdodge]

I learned so much from TDR about the infamous lift pump I thought that I would post about my experience in the hopes that it may help someone with theirs.



I had 110,000 miles on my original lift pump when I finally got around to installing a fuel pressure gage. When I did I had 7psi at idle, 5 at cruise, and could draw it down to 1psi at WOT. Emailed Cummins about these pressures and they said as long as I had positive pressure at the VP44 it was OK. Not content with that I called the dealer. They said the stock lift pump was NLA. They could perform the in tank retrofit. Price was $380 for the pump and $500 for installation but could be more since they had never done one. I decided that the known OEM type pump was a better option than the unknown in tank pump. I went to a Cummins dealer and purchased a Cummins lift pump for $160. It took 1 1/2 hours doing it from the top without removing the fuel filter housing or starter. This included a filter change also. We cracked the banjo/schrader bolt at the VP44, bumped the starter once, and had fuel flowing in less than one cycle of the pump. Tightened the bolt, hit the key and it started right up. Now we had 16psi at an idle, 12. 5 psi at cruise, and 10 at WOT. Thanks to everyone here this went smoothly.



As a footnote: The friend that helped me, his mother inlaw has a 99 2500 and is a full time RV'er. Tows a huge Holiday Rambler all around the country. Has 200,000 miles on the original VP44 and still has the original lift pump. Go figure!

 

[Texas Diesel]

I've seen a few 100,000 mile LP's doing just fine too. Cant figure out why.



Consider a Vulcan Big Line kit. Best $109 you will spend, it relocates the stock LP to near the tank too. Makes it easy to change LP's :-laf



And the LP is away from engine vibration/heat.

 

[bigdogdodge]

Thanks Texas Diesel! Where may this kit be purchased? I would like to look into it for my next lift pump replacement. Thanks again.

 

[Texas Diesel]

http://www.vulcanperformance.com/dieselperformance.html

 

[AKAMAC]

I carry a 10, 13, and 17mm with LP in my truck. My last one went 400 miles. Go figure. Warrentied replacement came in yesterday, I can do the change in 15 min now!

Mike

 

[bigdogdodge]

Hi Akamac,



Could you list your change out procedure for me? I would like to be able to change mine in 15 minutes! Many thanks

 

[keimmmo]

bigdogdodge,



I would relocate the lift pump and install high flow fittings now. Lift pumps seem to last longer and you get better pressure to that delicate VP-44. You can do the modification in a shop when you want... and it will make changing the lift pump along the road a lot easier!



Steve Keim

 

[AKAMAC]

Remove the supply line bracket bolt. Loosen the banjo bolts without pulling them out, if you are careful the rubberized washers will keep the banjos in place, push the fuel lines behind wire harnesses that are close to pump. Pull pump plug. With your right arm under the master cylinder this is easy.

Remove the back two pump mounting nuts completely, again, with your right arm under the master cylinder. A 1/4" drive ratchet is handy here.

Now remove the last nut on pump supporting the pump with your left hand.

To do this will require that you have a way to put yourself at belly level with the hood/fender seam. I have a sloped loading ramp at work I use. A park bench would work.

The replacement is in reverse order, except the banjo on supply side is finger tightened then the bracket is secured.

The only hard part is getting the pressure side banjo started, because of its location you don't have a 3d view, so you have to intuitively feel it threading in straight.

Hope this helps. Mike

 

[RMersiowsky]

I also had to recently replace the LP at 94K miles. Truck was running a little poorly at high RPMs on hot days. Ran great otherwise. Local dealer checked it out for $140 and said that I needed to replace the LP, fuel filter, and VP at a cost of $3300 before I should drive the truck again. Told them thank you, have a nice day, and drove the truck home.



I subscribed to TDR, asked how to do the work, got the answers and proceeded with replacing the filter ($20), LP ($162 from Cummins), banjo seal washers ($6) and new wire harness ($16). Saved about $3000 doing it myself. (Dealer wanted $30 just for the banjo seal washers. )



Only took me about 1. 5 hours to do the work once I got the tools and parts together. Truck started right up and is running great. I'm hoping that the VP is OK.



My next investment is a FP guage.



Thanks TDR members

 

[bigdogdodge]

Hi Akamac,



We did it exactly the way you described. Only thig was we didn't know what we were doing. I guess that is why it took 1 1/2 hourd compared to your 15 minutes. Thanks again for the info.