I put a BD Diesel low fuel pressure light kit a buddys truck. It worked great for 3 months, then the pressure switch went bad. I called Bd and they sent me another no problem. Now another six month have passed and the sender is not working consistantly. Any else had this problem? I was thinking of going to a machanical gauge. What psi gauge should I get?

 

are you using a needle valve or snubber to protect the sender?

 

I screwed the sender into the inlet banjo bolt to fuel pump. I'm not sure what ais ment by a snubber.

 

These pressure switches are unreliable. If you dont have the equipment and know-how to test it -> get a fuel pressure guage.

 

They are simple to check with a ohm meter. Sometimes it is open, if i tap it the sender will close. (go to ground). It ain't rocket sicence. I was asking if anyone else has had troubles with them.

 

the needle valve or a snubber limit the fuel pulses (water hammering) that ruin a sender. and yes it is common to ruin senders unless you limit the pulses. also mounting the sender away from the engine is a good idea as the vibration shakes the senders internals to pieces.

my set up orginally had my needle valve screwed into a banjo bolt that was in the vp, then from the needle valve I used a piece of hose to my mechanical gauge. I ditched this after getting an edge J/A. and an Airdog. I remote mounted 2 senders one fron Edge and a low pressure sender, this acts as a back up for each gauge, if one shows low pressure its a sender issue, if both show low pressure then its a pump issue

 

This truck is all stock, how big a mechanical gauge should I get. Is a 20psi too low, or should I get a 50-60 psi gauge?

 

depending on what your fuel pressure is, a mechanical gauge is better than a switch. normally the 50% range of the gauge would be good (if fuel pressure is 15#/ a 0-30 gauge would be good) so if everything is good the dial will be in middle of the range of the gauge. But a needle valve is still recomended for the same reason, to snub the pulsations that will wear out a gauge too.