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Yo Hoot
TDR MEMBER
I have had a FASS 150 HD fuel filtration system installed on my truck for 7 years now. Warranty is 6 years so figures... 7th year failure. Overall the system has been very reliable albeit noisy.
A few weeks ago I pressure washed the underside of my truck. That evening the FASS system came on all by itself. I was able to shut it off by cycling the key. Happened two more times that day. And if I remember, the dash lights came on while this was occurring so I assumed water got into something but finally dried out.
Fast forward, couple of weeks later... I start the truck and don't hear the FASS motor. Can't say for sure how long it wasn't working because you get numb to the sound after a while.
So I read the troubleshooting procedure. Knock on the side of the motor with a hammer to see if the brushes are going bad. No luck.
Test for power at the connector at the FASS... I read 12.1v and after a short time went to zero it looked like the ECM was commanding power and shutting it down with a no-start. Just like normal.
So time to get a new motor. It just so happens that FASS no longer makes the HD series and it's not so easy to find a replacement motor. They (FASS) claimed they were waiting for a backordered component and they would have units available around mid-May. I don't know if that happened since I did finally find one out there in the middle of the country.
So replaced the pump. It was a pretty big job for me as the fit is quite tight. Guess I should have taken the filters off and removed the wheel well liner... there's the first useful tip.
The brackets were all rusted up. The powder coating came off in sheets so I wanted to restore them with a new coat of good metal primer and black paint. Ended up using Duplicolor truck bed coating.
#ad
Got it all back together. Noticed there was no longer a port for the pressure sensor on the motor "T" block where I had my sensor originally. There is another place for the sensor so they stopped putting them in the "T". No problem. Just use the port labeled "G".
So I get in the truck and turn the key on..... NOTHING. No pump.
Did I get a bad pump?
So I decide to check the relay. I originally assumed the relay was good since I was getting 12v at the end of the line where it connects to the pump AND the ECM was correctly shutting the relay off after a no-start.
I find the relay and waa la... the terminals are all corroded. Pulled the relay out of it's socket. Got a new relay, cleaned everything up, loaded up the socket with dielectric grease and pushed the new relay in the socket. Put dielectric grease all around the base of the relay and loaded some into the back of the socket to help keep moisture out. I also wire tied the FASS harness up higher under the hood to help keep it away from water.
Turned the key on and I hear the motor.... barely. The new motor is a lot quieter! Once fuel started getting through it did get a little louder but not much.
All fixed up. What's funny is my buddy Aaron has a 2003 Cummins. Same FASS as me and close to the same age. His pump went out on him on his way to NY to pick up a big rig motor. He ended up throwing in an electric pump from AutoZone just to get by. When he came back here is what he had in the bed.... Cummins Big Cam 3-400hp
Since my old pump was still good i gave it to him. He installed it to use until his new one arrives.
In conclusion... check your relay on a regular basis to look for corrosion at the terminals. Maybe once a year. If you have a problem, check the relay first to avoid what I went through.
It appears water got into the relay terminals and caused the relay to turn the pump on after I pressure washed it.
Genos offers a really nice sealed relay pack. I actually have one. I originally purchased it for my offroad lights. I didn't install it yet. I decided not to install it this time for the FASS only because I had run out of time and weather to do the splice work. Maybe another time.
Mike
A few weeks ago I pressure washed the underside of my truck. That evening the FASS system came on all by itself. I was able to shut it off by cycling the key. Happened two more times that day. And if I remember, the dash lights came on while this was occurring so I assumed water got into something but finally dried out.
Fast forward, couple of weeks later... I start the truck and don't hear the FASS motor. Can't say for sure how long it wasn't working because you get numb to the sound after a while.
So I read the troubleshooting procedure. Knock on the side of the motor with a hammer to see if the brushes are going bad. No luck.
Test for power at the connector at the FASS... I read 12.1v and after a short time went to zero it looked like the ECM was commanding power and shutting it down with a no-start. Just like normal.
So time to get a new motor. It just so happens that FASS no longer makes the HD series and it's not so easy to find a replacement motor. They (FASS) claimed they were waiting for a backordered component and they would have units available around mid-May. I don't know if that happened since I did finally find one out there in the middle of the country.
So replaced the pump. It was a pretty big job for me as the fit is quite tight. Guess I should have taken the filters off and removed the wheel well liner... there's the first useful tip.
The brackets were all rusted up. The powder coating came off in sheets so I wanted to restore them with a new coat of good metal primer and black paint. Ended up using Duplicolor truck bed coating.
#adGot it all back together. Noticed there was no longer a port for the pressure sensor on the motor "T" block where I had my sensor originally. There is another place for the sensor so they stopped putting them in the "T". No problem. Just use the port labeled "G".
So I get in the truck and turn the key on..... NOTHING. No pump.
Did I get a bad pump?
So I decide to check the relay. I originally assumed the relay was good since I was getting 12v at the end of the line where it connects to the pump AND the ECM was correctly shutting the relay off after a no-start.
I find the relay and waa la... the terminals are all corroded. Pulled the relay out of it's socket. Got a new relay, cleaned everything up, loaded up the socket with dielectric grease and pushed the new relay in the socket. Put dielectric grease all around the base of the relay and loaded some into the back of the socket to help keep moisture out. I also wire tied the FASS harness up higher under the hood to help keep it away from water.
Turned the key on and I hear the motor.... barely. The new motor is a lot quieter! Once fuel started getting through it did get a little louder but not much.
All fixed up. What's funny is my buddy Aaron has a 2003 Cummins. Same FASS as me and close to the same age. His pump went out on him on his way to NY to pick up a big rig motor. He ended up throwing in an electric pump from AutoZone just to get by. When he came back here is what he had in the bed.... Cummins Big Cam 3-400hp
Since my old pump was still good i gave it to him. He installed it to use until his new one arrives.
In conclusion... check your relay on a regular basis to look for corrosion at the terminals. Maybe once a year. If you have a problem, check the relay first to avoid what I went through.
It appears water got into the relay terminals and caused the relay to turn the pump on after I pressure washed it.
Genos offers a really nice sealed relay pack. I actually have one. I originally purchased it for my offroad lights. I didn't install it yet. I decided not to install it this time for the FASS only because I had run out of time and weather to do the splice work. Maybe another time.
Mike
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