OK got 105K and starting to see some smoking and rough starts in the cold and occ. rough idleing. Thinking about gettting injectors rebuilt and putting on a fass fuel pump with the two big filters.
Even though mostly stock what do you think about adding 25 or 50 HP injectors?
Any other PM ideas?

 

you do not need the fass pump. total waste of money. get ddp to rebuild with 50 hp nozzles. get a smarty jr and a pdr camshaft. these three items removes most of the in-cylinder egr and gains you 6 mpg and 300*lower egt. here is the filter setup. we mount the filters just forward of the fuel tank. we run a fleet of dodges and recently installed one on a 06. there is two bolts through the floor board for a rear seat option at this location. some of our trucks use them others do not. get a 2" x 3" piece of angle iron 6" long. make a card board template that the two bolts and keeper nuts will go through hold the template on the inside against the 2" part and drill the two holes they will be about 5/8" i think and about 3 7/8 " between. center the holes on the 2" and near the edge on the 2" hold the angle iron over the bolts with the 3"part the furtherest away from the tank and drill a 1/4" hole between the two holes, keep drilling through the floor board. now after you mount the filters to the angle iron just simply mount it with a 1/4 grade 8 bolt. this is the only hard part the other items is easy. the total time including building the bracket is about 1 1/2 hours. i will give you napa numbers but they can cross reference to wix or car quest. the two bases are 4770 the water separator pre filter is 3374 if you think you must have a drain on the separator use 3406 the 2 micron filter is 3674. use a 3/8" nipple with about 1/2" space in the middle connect the two bases together observing the in and out. because of this the mounting plate on one filter base is about 1" further out than the other. install two 90* 3/8" barbed fittings on the bases and temporary bolt the angle iron up and hold the filters up to it. make sure everything clears and mark the one base that touches the plate to drill the three holes to mount the filters. next cut the feed fuel line at this location and bend the lines out a little and install 3/8 hose over the lines and to the barbed fittings. i put a small amount of flair on the steel lines. but i do not think it is necessary. Bleed the air out through the stock filter before trying to start it. use a gauge and do not change the filters until you see a four pound drop this should be about every 150,000 miles and the stock filter will never need to be changed.

your filter base has two inlets and two outlets on each base be careful to connect the nipple between the outlet of the first filter to the inlet of the second. only one of the bases get's the bolts as the offset places the second base about a inch away from the plate. we use to make spacers on the first ones and then decided they were not needed

 

I kept my oem filter for the water trap/prefilter and added a 2 micron after it. I mounted the 2 mic. behind the lt. fog light. Craig

 

Carl48
With my lift pump being on back of fuel filter should i just replace that pump and run with it?
I like your setup Im actaully going to use it, but first I need to figure out the lift pump, relocate to frame rail before filters?
Anyone else?????

 

firebill you show a 04.5 in your sig. the fuel pump is in the tank

 

i have an 04.5 my fuel pump was on the back of the fuel filter canister. been running a fass set up for four or five years now. replaced all my injectors at the end of the summer and added a 2 micron fuel filter set up from iron horse.

http://www.ironhorsegarage.net/dodge.htm

 

So my ride is a 04.5, RJM002 did you remove stock lift pump? If so, what goes there to replace where pump was (on back of fuel filter)?
Also did you install your FASS set up yourself, if so any comments good/bad?

 

I installed my FASS under the truck and a 2 mic filter and a fuel/water seperator. I first added the pump and then the filters. I also kept the OE canister filter as a backup. I put togather my own set for the filters and spent a little more than $100.

If you order the correct pump you will get an adapter that will replace the pump on the back of the canister and you will not need to do anything to the tank. I do recommend raising the bed to get to the fuel line connector on the tank.

The FASS is a noisy pump. I made mine a little quieter by reaming out the mounting holes on the pump and added some rubber between the mounting bolts and the pump bracket.

 

installed the fass myself. well, there is an aluminum block with an o ring that goes on the back of the fuel filter with the fass system. but after a few months i had a continued leak from that o ring. and after several replacements the threads on the fuel filter canister were a little on the worn side. i then installed a 2nd gen fuel filter canister which is a little different. no aluminum block set up like on the 3rd gen fuel filter canister. 2nd gen canister had female threads for a fitting which solved my problem.

 

Excellent easy to understand write up Carl48. Fabulous. I'm going to do this in the spring when it warms up out there...

 

Highly recomend you look into AirDog as another option for Fass. Very similar to Fass and many have been happer with them. I had GDP fuel pump for many years and replaced it with an Airdog when the GDP pump failed. Read around on bot Fass and AirDog and make your own decision. Whne I researched the Airdog made sense ot me and has been working well. I also hhave a 2 micron CAT fliter inline before my CP3 and with 168k on the speedo have not had any fuel related issues to date.

Best of luck with your truck..

 

i learned something, i never knew that the early 04.5 had the external pumps. we did our 03's two different ways the ones that failed under warranty they moved to the tank the ones that failed after warranty we installed a raptor pump near the filters and fed the pump before the filters. one truck still has a stock pump, we ran two lines back to the filters and cut them in after the pump.

 

Thank for that link. It's the best deal I've found on that setup. I have a concern that you may be able to speak to. It looks like it would pick up a lot of vibration from the engine along the bracket. Does it shake as bad as it looks like it would?

 

nope. its been on since sept. no issues. vibrates a little obviously when truck is running. only drawback to having it mounted there is trying to check the power steering fluid-real tight-but luckily-checking the p.s fluid is infrequent and /or can be done when changing the fuel filter.

 

has anyone tried a severe duty filtration kit for cummins equipped trucks ?