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Engine/Transmission (1998.5 - 2002) Yet ANOTHER transfer pump story

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2nd Gen Non-Engine/Transmission brake cyn.

Engine/Transmission (1998.5 - 2002) I know drugs are bad... but...

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TP replaced by a dealer under warranty following failure and break down on the road 3,700 miles back at 62,700 miles. The new pump showed 13# of pressure at idle, never less than 7# running wide open under full load at high RPM pulling a 11K 5th wheel travel trailer up a mountain. Yesterday, I noted pressure of 6# at idle with what I would describe as nearly constant fluctions between 6# & 10# that seem to have no relationship to what the truck is doing - this is in an unloaded condition. It seems that accelerating from idle tickles the pump to increase pressure - this is the EXACT OPPOSITE of the "normal" operation I have noted since installing the guage over a year ago.



Sensing an iminent TP failure based on what I have read here, I took the truck to a dealer. They did a flow test. Apparently neither Dodge or Cummins seems to care about pressure or pressure fluctuations. The truck passed the flow test. I was told that it was stupid to have a FP guage because all it did was to cause unnecessary worries and trips to the shop. I told them I thought the purpose of the guage was to alert me to a problem before I broke down on a dam&*d interstate on a weekend night 100 miles from a dealership with the trailer. I told them that there are hundreds of posts on this forum RE TP nightmares - I told them that the system design was faulty and that DC knew it. The service writer told me that in ten years of selling Cummins engines, they had only seen one TP failure. This is one of the largest Dodge dealers in GA:confused:



My questions are, should I put a TP & the tools to replace it on board? Should I go ahead & replace the TP on my own disregarding my warranty coverage? Or should I rest comfortably and ignore everything I have read here? Or should I start a cash pool RE how much longer this thing will last?



Final question - I have never read anything here about sending unit or guage failures. Is this something that I should be looking into?
 
Does your fuel pressure gauge have a fuel isolator or is it hooked up to a direct pressure tap? Or is it have an electric sending unit? I have seen transfer pump do this and I have had several cases where the fuel gauge is tapped directly in to a pressure tap with no isolator start doing this several thousand miles later. I have installed a tee in the pressure line to the gauge with a 2 inch nipple pointing up capped off to have the trapped air act as a damper.
 
Ramtough said:
The new pump showed 13# of pressure at idle, never less than 7# running wide open under full load at high RPM Yesterday, I noted pressure of 6# at idle with what I would describe as nearly constant fluctions between 6# & 10# that seem to have no relationship to what the truck is doing - this is in an unloaded condition. It seems that accelerating from idle tickles the pump to increase



I have the same prob. Pressure runs at random 5-16 lbs. Idle,crusing,or WOT... doesnt matter.



No drop at WOT either. :confused: (see truck profile)



Was concerned that the new pusher (5000 miles) was bad or maybe the gauge. I use a cyberdyne digital and its new also. I have a holley black pump waiting to be installed. Never thought about air getting in the sensor. Hmmm... gonna have to try the "t-fitting" if the new pump acts the same. Was curious if the main pumps overflow was getting stuck open. Have run injector cleaner through it several times (in tank and filled filter housing) with no help.
 
Ditto the comment about the gauge. Verify that it is showing actual pressure, and has not malfunctioned.



Yes, I would buy a pump (from Cummins or some other big rig shop) and keep it and the tools under the seat.



Service manager is full of s**it if they have only seen one failure, that or they do not sell/service that many 2nd gens in the short time that they have been open.
 
Ramtough, Lift pumps seem to last a vastly different lenght of time from pump to pump. I replaced mine about 6 months ago. It held 15psi at idle when new and now reads 11-13psi. I am also down to 7-9 psi crusing at 75mph down from 10-11psi when new. Do you have a pressure guage that you can check your guage with? I have a guage that we could use for the test. I'm in Acworth so we could do this pretty easily.
 
What a load of BS. I had problems 3rd LP post 100k. Purchased from Cummins, 10-PSI idle 2 PSI WOT. I was furious, took it off and returned with it the next day, counter guy was willing to "sell me another one and let their Warranty Manager :confused: handle the other one". WTF is a Warranty Manager. I took it home re-installed it and went to the Cummins site - found customer comment section and did an e-mail reply. I mentioned the Cummins dealer, names of everyone I spoke with, dates & times how often I had to call due to no reply. What my previous pressures with pre 100k replacements the dealer did and pressures with this pump, what I was able to fine as far as specs from DC (10 PSI regardless of throttle position merits replacement of LP - that was at the time - this is not valid now - unfortunately) and lastly that I belonged to a group of 15k + - at the time now 20k - people owning these trucks that were waiting to see what was going to happen. I received a reply the next morning stating that Cummins was very sorry for my problems with their product and unfortunately there was nothing that Cummins Corp was able to do to resolve my issue. They recommended I continue to work with my local Cummins shop to resolve - they thanked me and my organization of members for our support of Cummins products and wished me well. I was livid!!! #@$%! Ironically by noon that day I received a call from the "Warranty Manger" apologizing for taking so long to get back to me and requesting my address in order that he could send a refund check :confused: :--) :eek: :-laf . I asked how to handle return of the other pump and was told to throw it away. 4 days later I received the check. Oh, yea, Cummins Corp. can't/doesn't handle customer problems HA!



I would check your gage, sender and as mentioned by another member if you don't have an insulator of some sort between the pressure tap and sender it is inevitable that the sender will fail. I'd compare your gage readings to a mechanical one and go from there. Good luck.
 
LP failures

I thought I read of a few failures with the FASS system too. I'm going with a spare lift pump and fuel additives (for lubrication) to address the problem. So far... all's well

Like everyone else... I'm not real happy with this LP thing... but the alternatives are exspensive and by know means fail-safe. What happens if the motor fails on the Air-Dog or FASS. Will they replace it... under warrenty??

Or. . do you just buy a new unit?

Anyway, they're all just mechanical devises. . that can and will fail. Do whatever your wallet (wife) allows.



Mike
 
Update - got the truck back from the dealer. Drove it about 250 miles yesterday. LP seems to performing as it should. 12-13# idling and 10# @ 75 MPH cruise unloaded. The dealer did not change the filter. I wonder what could have caused intermittent abnormal (my term) activity in the pump?
 
Ramtough said:
Update - got the truck back from the dealer. Drove it about 250 miles yesterday. LP seems to performing as it should. 12-13# idling and 10# @ 75 MPH cruise unloaded. The dealer did not change the filter. I wonder what could have caused intermittent abnormal (my term) activity in the pump?



Corroded connections, sediment/grit in the fuel wedges the vanes in the closed position on the impeller hub, bypass valve getting cranky.
 
I looked over at the pre and post gauges one day while my wife was driving and they were both bouncing from 0 to 13 psi... she said oh yeah they've been doing that for a few miles... Another occasion, I noticed both gauges were at 0 psi, shutdown/re-start has cleared the 0 psi problem a couple of times now. Idle psi runs 13 pre & 12 post, cruise is typically 10 & 9, however you would think that the gauge needles are directly connected to the fuel pedal and that is with the box on 1x5 or off. Without using a feather foot the psi can drop to 5-0 when mildly pulling away from a traffic light. This has been happening for several months now, I've been living on borrowed time and not enjoying the truck's power. I can keep the pressure above 5-8 psi by being careful however new lines, fittings and a frame mounted pump are going in this month.
 
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