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Engine/Transmission (1998.5 - 2002) Replaced VP44 -- and solved mystery?

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Engine/Transmission (1994 - 1998) New truck, a few ?s

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TDR Folks,



I replaced my VP44 on Saturday because of recurring and persistant P0216 error. I've been fighting with this error since November, and just couldn't figure out why the pump went bad. This pump replaced the original 30K miles ago (insalled by Dodge), and I've monitored fuel pressure since installation, and have really babied it. The only issue I've had was running out of fuel once (about 6 mos prior to problem appearing).



So, I replace this pump, and after I button the truck up, take a close look at it. A problem (perhaps THE problem?) was obvious -- the timing key on the pump was sheared perhaps 1/2 of its width! So, obviously, the timing could and would be drastically affected.



What, I wonder, would cause this to happen? Its clear that the pump drive gear was moving and the pump shaft wasn't, but there would have to be considerable resistance in the pump to cause the gear to spin on the shaft.



Or, could the damage have been done when this pump was installed?, e. g. , the key wasn't precisely lined up, and the tech applied so much torque on the shaft nut that it just sraped a portion of the key off? If so, why did it run fine for almost two years? Very peculiar.



I'll post a picture later so you all can take a look. I'm going to have the pump tested and rebuilt if necessary, but am hoping that this $1 key is that needs to be replaced!



Thanks.



Craig
 
Craig

I'd be interested in what you find. I also have a recurring P0216 code at 73k miles and I just replaced my factory LP to regain 15psi at idle.



Thank you

William



PS it would be nice to see your signature
 
I'll be sending this pump to SouthEast Power Systems (www.se-power.com) in Orlando, FL. They are one of about 8 shops in the US that actually have a VP44 test stand. Hopefully, the keyway is the only thing that needs to be replaced. We'll see what their tests reveal.



Craig



(WTBurke -- sig included. Thanks for the suggestion!).
 
Pic 1: VP44 shaft with keyway partially removed. Note the shape of the keyway.



Pic 2: VP44 shaft w/o keyway. Note damage where keyway was pressed into shaft.



Pic 3: Keyway. Note how deformed it is!



Now, how could this have happened? Not enough torque on pump nut?
 
I would think the either the key was malformed to start with, allowing the gear to slip back and forth enough to start shearing it, or the gear was not drawn up tight enough to prevent it from "working" on the key. Keys are obviously much softer metal and any slop will kill them.
 
Don't overlook the possibility of a problem with the GEAR - it might be a larger part of the problem than the VP-44 shaft and key - and COULD cause a similar problem with any replacement pump...
 
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