Engine/Transmission (1998.5 - 2002) Who said changing Banjo Bolts was a 15 minute job?

[LBTRS]

Just spent 2. 5 hrs changing the banjo bolts, man that one under the fuel filter canister is a pain. I spent a hour looking at it trying to figure out how I was going to reach those three under/behind the fuel filter canister then decided removing the canister was the best option. Took about 1. 5 hours to change them after I came up with a plan. About 30 minutes of that time was getting the truck running again after emptying the canister and fuel lines of all the fuel. The trick to changing them seems to be removing the bolts to the fuel filter canister so you can turn it sideways and get a wrench on the banjo bolt underneath it. This also gives you access to the other two behind it. I wonder what method allows changing the banjo bolts in 15 minutes like I was told?

 

[jlccc]

Originally posted by Ray Trautman

Just spent 2. 5 hrs changing the banjo bolts...

Guess you can't say 'totally stock' anymore can you?

 

[Lurch]

I did the work in 15 min. , maybe less. Didn't move the filter at all.

Spent 2 hrs looking for the @#%$^$%%* washer that I dropped though.



Lurch

 

[LBTRS]

Really, 15 minutes huh? I wonder what I'm missing? I can't see or reach the ones under the fuel filter canister with the canister in place.

 

[Big White Beast]

Reached mine from the bottom.......

Still took way more than 15 minutes. Not 2. 5 hours though.



Only prblem from the bottom is you get a nice bath. Not gushing just enough to run down your arm and soak you a bit. The old lady did not appreciate my #2 cologne.



Garrett

 

[Steve Campbell]

So what did that 2.5 hours....

gain you in fuel pressure and power?

 

[John Berger]

I did mine in about 45 minutes.

 

[zimman20]

I didn't have much trouble getting to the one under the filter canister when I changed it for a banjo bolt to hook up my FP gauge. The bigger pain in the butt was trying to get the 1/8" NPT fitting started in the banjo bolt, weird angle to work at.



Would have been more irritated if I hadn't checked the banjo bolt for fit of the 1/8 NPT adapter PRIOR to installing the banjo in the bottom of the canister. Had to re-tap the banjo bolt to accept the adapter, something I knew to look out for thanks to other members posting the same problem with Ray's banjo bolts.



Don't know about the ones behind the filter, didn't do them. I imagine they'd be arm-busters.

 

[LBTRS]

Power?

Should I be expecting a power increase steve? I was expecting help in my fuel pressure numbers (will check tonight as it was dark by the time I finished last night) but was not expecting a power increase.

 

[John Berger]

Ray, I wouldn't expect an increase in power. What you've accomplished with the bolts is less restriction in flow. The increased flow will be a benefit when you BOMB.

 

[Steve Campbell]

SOP meter on 3 diff....

... erent CTD's said power gain with drilling banjo's.



Probably just the testosterone kicking in.



It would be nice to know (maybe someone will do this at Spokane) before and after Dyno run #'s with just the banjos as the only mod in between.

 

[LBTRS]

Steve,



Hope that's the case, will try it out tonight when I pick it up from the shop doing the south bend clutch install. I'll let you know.

 

[enrightkp]

I think possibly the difference here is the year of the vehicles. My '99 doesn't have a fitting on the bottom of the fuel filter canister, both fittings there are on the top and readily accessable. The only difficulty I had were the two on the lift pump and dropping one of the washers repeatedly. I replace all 5 banjo fittings (1 on VP-44, 2 on fuel filter housing, 2 on lift pump) in about 1/2 an hour.

 

[tmacc]

Ray,

As you found out removing the two 10mm bolts that attach the filter housing to the block and let hang off to the side makes it a whole lot easier to install the bottom BB. It also makes it easier to get to the ones on the lift pump too. Sears makes some stubby combo wrenches that make it easier to work in tight quarters. They definitely help. BTW did you drill out the banjo fittings between the lift pump and the filter housing. Just pull the rubber line off (this is after you have removed it from the truck) and drill them out to 3/16" or #8 drill bit. I stuck them in a vice and used a cordless drill. Piece of cake. These are major restriction according to experts. Actually, IMHO you aught to relocate the LP back by the tank and run a new line to a Weber adapter (Summit PN # 991944) and eliminate the banjo fittings all together now that you have the banjo bolt thing under your belt.

 

[TStinson]

I got the set of five from Geno's. So far have only changed the easy ones - two on top of the filter mount. Been pondering what fun the two on the lift pump were going to be - thought about removing the filter can to access those.

Note - did not need the tapped hole bolts since the 1999 has ports on top of the filter mount for pressure gauge taps.



Did notice when I pulled the one at the pump, that the holes in the stock banjo were already as large as those in the one from Geno's. Emailed Ray T. (manufactures the modified bolts) - he said had never actually seen the pump banjo bolt on the 1999, so he could not comment. The stock banjo's @ the filter mount were indeed smaller than the modified ones though.



Have any other of you 1999 owners run across this?

 

[Big_Daddy_T]

I ran across one that was shorter in length with large holes. Because it was only one and not a pair I assumed it came out of my injection pump. I found no one else reporting the same anomaly. Although this is my third injection pump so a few techs have had a chance to swap it for some unknown reason.

 

[Steve Campbell]

When I first pulled mine out...

and drilled them, the on in the injection pump already had the bigger holes in it. I just figured Cummins said "we need this size" and Dodge put the rest of them in with the smaller size orifices.