Have a 96 1-ton dually with no mods other than 4" exhaust. recently suffering a big loss of power going up hills on the freeway. I can only get up to about 40 and have to drive on the shoulder to keep from getting run over by semi's. once back on flat road seems to drive normally again. Have change fuel and air filter and the lift pump. I've heard horror stories about bad lift pump ruining the injector pump, could that be my problem. truck has 126,00 miles and has ran great up until now, any ideas on what my problem is?

 

Is it smoking?? can you hear the turbo spooling?

 

Thanks, It dosen't smoke normally, but I notice some white/gray smoke during the loss of power, but not a lot, just a puff when I try to speed-up during this power loss. I don't think I hear the turbo spooling, but I'm not sure, but during normal driving on flat roads, everything seems normal. It is more likely the turbo then dirty injectors or bad injector pump?

 

This is where a boost gauge comes in handy.
Check that none of your intake system boots are blown off or cracked. Also check that the line going from your injection pump up over the engine to the turbo is ok.
Your timing could have slipped also.

 

Bill, what part(s) actually move/slip/fail when the timing "slips" on a CTD engine? Timing chain, or is there a gear that slips , or??

On the turbo intercooler boots - those on our '96 were worrying me, so I finally got lucky on a like-new pair on ebay.... better to have them waiting than to have to shell out big bucks in a "need it right NOW" situation!
I was picturing the "massive duct tape patch to get it home" thing Having those new boots wrapped up in a big freezer bag behind the seat is a much better feeling.

 

What are your RPMs. Had an overflow valve go bad ans cause that to happen one time it would not go over 2000 no matter what.

 

Also check the shutdown soleinod.I had the same problem.Could hardly climb a hill.Found the linkage was out of adjustment and wasn't pulling the pin far enough in the pump...

 

Take your intake boot off and check turbo, spin it, check your in and out play and check sides of body next to the fins for gouging. Those boots on the intercooler could rub on the frame and a pin hole will stop you. Check the intercooler bottom for rot. That **** screen in the fuel heater almost stopped me. Make sure boot on the intake manifold is square. That much loss of power makes me think its in the air charging. If all else fails a compression test. Go thru all the easy steps first. Also see if your waste gate moves in and out when playing with the throttle.Steve

 

The gear on the injection pump shaft can slip because it isn't keyed.
It's not keyed because different gear positions on the shaft are how timing is adjusted.

 

I agree with Infidel, He is always (Can I say "Always"?) right on with his advice. I had a similar problem just yesterday while hauling horses. It was an intercooler boot, It was the one on the passengerside, under the lower radiator hose, it rubbed on the sheet metal edge of the fender well and made a 2 in long slit in the boot. I had duct tape and tools, so I took it off and taped the snot out of it, put it back on and back on the road. Enough to get me home. I'm going to spend the $$ and get new ones, and keep old ones as spares. Where can I get a good price on boots?????? Hope this helps.

 

Prices seemed to be fixed, I've found them all to be about the same.
Personally I like doing business with http://www.piersdiesel.com/

Every truck I work on for the first time I check the lower passenger side boot and bend the sheet metal back so it doesn't cut the boot. May look like lots of room but the boot can swell to almost twice it's size under high boost.
Sometimes it's hard to see if the boot is cut, you have to push on it with your finger to be sure.

 

Thanks for all the helpful advice, I've checked some of the things mentioned like the rubber boots and the turbo and all seems visually o.k. To further test the truck I took it out today and drove it hard in third and fourth gear, which I usually don't do, and it accelerates normally up to where I normally shift, but if keep my foot down it quickly reaches a point where the power completely flattens out, the truck losses lots of power and clouds of white smoke pour out the tailpipe. Even after letting off the pedal, it takes about fifteen seconds even on flat road before the pedal responds normally again. This loss of power and smoke happens at about 3000 rpm's in third and about 2400 rpm's in fourth. I think I'm hearing the turbo spin, but it has never seemed particularly noisy or noticably whining. I haven't cleaned the prefilter screen yet but thats next. So, what I thought was loss of power on freeway hills will happen anytime if I go faster then normal in other gears. The smoke lets up as soon I take my foot off the pedal, but normal power dosn't return until I've driven at low power for about 10 - 20 seconds. I hope this further helps pinpoint the problem I'm having, and I sure appreciate the help you guys have given me, I don't know much about the technicalities of a diesel engine except for changing filters. I've had so little engine trouble with this Dodge or my 86 Ford 6.9, that I haven't worried much mechanical issues. Thanks again, John in Centralia, Washington

 

Well.............Maybe a fuel problem. Too much fuel, Not enough? Is Air getting sucked in to the system when there is high demand for fuel/under full throttle?

I'd still check/change all the intercooler boots.

 

Which transmission do you have? You say it loses power and smokes at 3000 rpm in 3rd, and 2400 in 4th.

What I'm wondering is you say it only has a 4 inch exhaust as mods, yet the motor will turn 3000 rpm. My 97 defuels hard at 2800, and I can't get it to 3000 on the highway, but I can free rev it. Might have to check into the pump and see what's all in it, I think it has more mods...

 

I finally took the pre-filter apart and sure enough, the screen was completely dirty and clogged and looked like very little fuel could get through. I ordered a screen kit from the dealer and will install it tomorrow and take it for a test ride and hope that my power loss problem was this simple instead of a bad turbo or something related. Thanks again for all the help, I couldn't have done it without you guys. John, Centralia, WA