2005 3500 nv 5600 used to pull a 50 foot three car which normally grosses 28,000 pounds. Engine will cut out while pulling hills normally in the 1800 to 2000 RPM range. Doesn't set a code in the computer. Truck has 360,000 miles and recently changed all six injectors. This is been an issue for about two months now this occurs more frequently and will occur while cruising at 1700 RPM range. There is no rhyme or reason to when it will happen, it may happen three times in a row or it may not occur for miles. Seems to happen least when the engine is being lugged up hills, almost always happens as soon as you make the down shift and bring the RPMs up. I thought maybe it was boost related and unplugged the wastegate solenoid, didn't fix the problem only set the wastegate solenoid code. This bucking or cutting out has happened thousands of times now and is never set the check engine light don't know how to fix this,any ideas are appreciated.

 

Replace the fuel filter nd check fuel flow to the CP3 pump. Must have min of 430ml in the graduated cylinder after 10 seconds of fuel pump running. Bump the starter to get fuel pump to turn on. QUick test would be remove fuel filter and drain fuel from housing. Bump starter the fuel filter housing should fill more then half way in ten seconds. If not you have plugged pickup or faulty lift pump, You could drain fuel filter housing again and measure fuel obtained min 430 ML. You can obtain some clear plastic tubing about two feet should be long enough. Then attach to fuel drain bottom of fuel filter housing, run it to graduated container measuring in ML. to test quantity. Before replacing pump check volts and ground at pump module.

 

I was working under the assumption if it was a fuel problem it would set a low rail pressure code. I have changed out the in tank fuel pump with a unit from O'Reilly's auto parts about 100,000 miles ago and this is probably way past the life expectancy of these junk parts

 

Just picked up the truck from the diesel injection shop after 3 days there. They were able to duplicate the problem by rolling on an off the throttle at speed. Still won't set a code. Also able to simulate the noise by turning off the key and then turning it back on. It makes that same popping noise. No solution so far.

 

My truck recently started something similar. Under hard acceleration the truck just shuts off around 2300rpm...falls flat. Let off the accelerator and it comes back to life. If I ease back into it I can get it to wind up a bit more but it will eventually fall over again. I can cruise at 75mph/2300rpm and its fine (so far). Mash the accelerator and she just shuts down like you tuned the key off. I haven't tried the fuel filter yet. I'm thinking the worst but hoping for the cheap/easy fix. Its been a great truck..231,xxx miles. Original clutch too...Did I mention I really like my truck?

 

had a similar problem, shop that did the injectors left one of the injector nuts loose, melted the injector stud. i was able to replicate finally for them after 10 months of intermitent symptoms by holding the brake pedal and loading the engine while 1/2+ throttle