Like others have said.. get the pressure gauge... its going to tell you alot.. and point you in a direction... the pick up tube is terrible on the 1st gens.. attached a pic.. that's a 3/16th drill bit in the hole for the pick that is inside the tank..
JDGnut

 

Wow that is terrible. Well soon as i finish modifying the vacuum source im going to try and see if any of the wiring or the broken line fixed anything. If not im going to blow the pouch off and see if that fixes it. If it does out comes the tank. At least it is supposed to be nice the next couple days.

Chris

 

There's no "sock" on the fuel pickup. It's a screened basket built into the bottom of the pickup assembly. If you could get enough air into it to take it off you'd explode the tank.

Ever try to buy a new pickup assembly for a 1st gen?

 

Well here is the news. I solderied all the wires and changed to ring terminals. The banjo bolt going to the cylinder head from the top of the fuel pump was broke so i fixed and replaced that. While i was in the pump i decided i would turn the star wheel 1 turn and put the fuel pin on its deep side. I took off the color on the fuel screw but didnt change anything just was getting it off for later use after i knew the truck was okay. Tried to start the truck and nothing. Just cranks over. So i loosed all the injector lines and cranked it off thinking there was air in the lines closed the first 3 and cranked then closed the last three and cranked and still nothing. Tried the bleeder screw that comes off the lift pump and then pumped by hand and fuel came out so shut the bleeder back up. Tested for voltage at the Fuel Shutoff Solenoid and its getting 11.8 volts. I have a new lift pump that will be here in a half hour "Delivered to the house gotta love friends at NAPA". Is there anything else you guys think of why it wont start now?

Chris

 

It sounds like it's not fully comming in or out of gear in the t-case. That's the only way I could think of that it would sound so bad in 2wd and nothing in 4wd. 205's can be hard to shift at times. Try unlocking your hubs first to releave the tension on your drivetrain.

 

You might try to remove the fuel shut off solenoid and pull out the spring and plunger. They have been known to stay in the shut position thus restricting flow to the high pressure chamber. After you gut it and reinstall it you will have to use the manual shut off lever to shut to pump off. You can either replace the solenoid or join the pull cable crew.

Bob

 

Took out the Fuel Shutoff Solenoid. The plunger actually looks brand new and no signs of wear or anything. Now shouldnt i be able to ground the body of the solenoid and tap the top terminal with 12 volts and it should move showing that it is in good condition?

I tried this with my battery charger on both 2 amp and 6 amp modes and it doesnt move at all when i tap the top terminal. But im not sure if that would even show me anything.

Thanks
Chris

 

Yes, if you put the solenoid body in the negative clip and touch the positive clip to the top terminal, it should suck the plunger in.

 

Okay well problem solved. At least one of the problems. It has stopped falling on its face. Total list of things i have done to fix the problem. Not sure which one fixed it though..

1) Rewired Fuel Shutoff Solenoid and KSB Solenoid with Ring Terminals and soldered all connections.
2) New Lift Pump
3) New Fuel Filter
4) Blew out the line from the lift pump to the tank.
5) Fixed Broken Hard Line that ran to the top of the High Pressure Pump
6) Removed Fuel Shutoff Solenoid, cleaned it up and made sure it was working by grounding the body and applying 12 volts to the terminal.
7) Fixed grounds on the Radiator Support

As far as problem 2 with the transfer case im still having that problem. I was hoping some magical way it would all solve itself..

So that should cover it. The problem now is while i was in the pump i did the following.

1) Turned Fuel Pin to Shallow Side
2) Turned Start Wheel Down 1 Full Turn
3) Screwed in Fuel Screw 1 Turn
4) And Fixed the Boost Reference Line ontop of the High Pressure Pump.

The truck feels like a totally different truck. And now like everybody else i want more.

Thanks for all your Help!
Chris