Engine/Transmission (1994 - 1998) What happened - need counsel

[CKHeller]

Hi Group,

My truck has been running quite well, starting easily, very little smoke except when I stomp on it and then only for a little bit, excellent acceleration smooth ride. I had a lot of repairs when I first got the truck but for the past 4 months it has been a pleasure to drive. Last week My wife's Mercedes needed to go into the shop for repairs and she borrowed the Dodge to get back and forth from work. I am recovering from surgery and not driving so I thought it would be good for the truck to get some road time. The first day she had no trouble. On her way to work on the second morning she said it suddenly started running rough and trying to die out on her but then it would recover, blow out black smoke and run rough. That happened a few times and she got stopped at a light and the truck died and wouldn't start. She was only a half mile from a Dodge dealership so she got towed there. They first told me it was the fuel solenoid shutdown. I hated to pay them for the labor but I'm not up to it at the moment and told them to go ahead. After they did that they called and said it is running very poorly, difficult to start and pours out gobs of blue/black smoke. They recommend replacing the injection pump or to take it to a Cummins shop near here and have it rebuilt. I'm not terribly mechanical and very inexperienced with diesel engines but not stupid either and don't understand this and have been reading a lot of old posts here and it doesn't seem to me that the IP would just suddenly go out like that and the FSS going bad wouldn't cause the IP to suddenly go bad either. Could some of you experienced fellows chime in here and let me know what might have happened and what to do now? I don't mind getting conflicting theories here. I've paid for the FSS replacement and will get a lift to pick up the truck tomorrow morning. This is not what I need just before Christmas.



Kru Heller

Powhatan, Va.

94 2500 reg cab, long bed, 4WD, 5 Speed

 

[Joe G.]

A little trouble shooting is needed instead of just replacing expensive parts. Hopefully, a TDR member near you will volunteer to take a look. Timing could have slipped. Does it have an exhaust brake on it? If so it may be stuck closed. Mine did that once. Amazing cloud of smoke. An intercooler boot may have torn or slipped off. Anyway, you need someone to look at it that won't charge you the hourly rate Dodge wants. Especially since they obviously don't know what to do.

 

[CKHeller]

A little trouble shooting is needed instead of just replacing expensive parts. Hopefully, a TDR member near you will volunteer to take a look. Timing could have slipped. Does it have an exhaust brake on it? If so it may be stuck closed. Mine did that once. Amazing cloud of smoke. An intercooler boot may have torn or slipped off. Anyway, you need someone to look at it that won't charge you the hourly rate Dodge wants. Especially since they obviously don't know what to do.

Thanks Joe. A little knowledgeable help would be appreciated. I do not have an exhaust brake. I'm really dissapointed with the dealership.



Kru Heller

Powhatan, Va.

 

[Flinty]

Also, check for water in feul, the sensor doesn't always catch it and a little water will make an impressive cloud of smoke. Was the tank full while it sat around? Condensation is a possibility in the cool weather. I always start simple and cheap then go from there. Hope this helps. Luck. J.

 

[CKHeller]

Also, check for water in feul, the sensor doesn't always catch it and a little water will make an impressive cloud of smoke. Was the tank full while it sat around? Condensation is a possibility in the cool weather. I always start simple and cheap then go from there. Hope this helps. Luck. J.

Thanks. I don't "think" it was water in the line. It was a little over a quarter full so I guess it could be possible but it happened before the big drop in temp here and the idiot light for water in line works and didn't come on also the filter/separator is new. When I get the truck back tomorrow I'll hit the button and see what I get out.



Kru Heller

Powhatan, Va.

 

[DBrickel]

I would start with checking for water in fuel, fuel filter etc. Might have even got some bad fuel. I have been shafted by the dealer couple of times and won't go there even for an oil change. Where do you live? Maybe someone here can recommend a shop near you or you might have a local Tdr chapter where some bombers might help

 

[EHarvey]

Thanks. I don't "think" it was water in the line. It was a little over a quarter full so I guess it could be possible but it happened before the big drop in temp here and the idiot light for water in line works and didn't come on also the filter/separator is new. When I get the truck back tomorrow I'll hit the button and see what I get out.



Kru Heller

Powhatan, Va.

just a shot in the dark , but does this truck have a f. a. s. s. fuel system on it.

 

[CKHeller]

Where do you live? Maybe someone here can recommend a shop near you or you might have a local Tdr chapter where some bombers might help

Thanks. Powhatan is in central Va. about 30 minutes west of Richmond. I'm only 3 miles from Rt. 60 and less than 10 from 288. If anyone wants directions they can Email me privately.



Kru Heller

Powhatan, Va.

 

[KingS]

Watch out see if there is a tdr member near you that can help work on it the dealers don't know enough about the diesels to fix it and not stick it to you for price especially injection pump they know nothing about it so they just replace stuff best have a cummins diesel shop work on it and pay the hire labor then the dealer.

 

[CKHeller]

just a shot in the dark , but does this truck have a f. a. s. s. fuel system on it.

Not to my knowledge.



Kru Heller

Powhatan, Va.

 

[CKHeller]

Watch out see if there is a tdr member near you that can help work on it the dealers don't know enough about the diesels to fix it and not stick it to you for price especially injection pump they know nothing about it so they just replace stuff best have a cummins diesel shop work on it and pay the hire labor then the dealer.

Thanks. If I haven't heard from a local TDR member willing to help by Monday I will find and contact the Cummins shop that the dealer's mechanic supervisor said was not too far from here.



Kru Heller

Powhatan, Va.

 

[Vaughn MacKenzie]

Kru one thing that happens sometimes is the fuel heater shorts out, melts the connector plastic and makes a hole in it allowing air to be sucked in. If it's pulling in a fair amount of air it'll run bad.



Here's something you can try: get a clear container like a 2-liter soda bottle, then stick it over the end of your fuel filter drain hose. Start the engine then push on the drain to open it. If it pumps out fuel with strong flow your lift pump is working fine. Also watch for foamy or aerated fuel. With the hose end at the bottom of the bottle the fuel shouldn't foam up and be clear once there's a few inches of fuel in the bottle.



Since you have the older style filter with the drain piece in the bottom of the screw-on filter it could be a little tricky but I think it's worth a try.



Also before doing this take a flashlight and look at the fuel heater to see if it's wet with fuel around the connector. Here's a diagram

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and check out this site for quite a bit of good information and part numbers on 12-valve engines: http://dodgeram.org/support_pgs/diesel_ix.htm



Good luck and keep us posted. Dodge dealerships for the most part make terrible diesel mechanics, especially on the older mechanical engines which have no computer they can plug into to tell 'em what's wrong. The scary thing is they're required to think, that'll most likely spell distaster

Don't let 'em talk you into an injection pump, it's very unlikely to be the problem.



Vaughn

 

[CKHeller]

Thanks Vaughn, I will do those things when I get the truck home tomorrow and report back with results.



Kru Heller

Powhatan, Va.