First off I have an early 03 250 hp dodge 2wd with 195k miles and bone stock. I also have no gauges but have ordered the banjo bolt with snubber from Genos so I can install a fuel pressure gauge. Last year the lift pump went out that was mounted on the filter housing so I installed a Fass DDRP. Last week while driving during acceleration it started to fall on its face like it was dieing then would clear up after couple hundred yard and run fine. It got worse during the next couple days but never would quit. One day I drove it to work and it would barely make 50 on the interstate, on a city street it would only get up to 30. I pulled over and you can rev it up and hold the rpms in neutral with no problem.
The pump probably has less than 20k miles on it. I change the filters every 10k or so and run the two micron Baldwin filter which is downstream of the pump. I changed the filters about a week before the first sign of a problem.
This afternoon I figured I would check the filters again. I drained the fuel canister and removed the filter and it was clean. I left the drain open and the filter canister open and had my wife turn on the key. The pump only makes noise for about a second then stops. It seems to be a little more "harsh" of a noise then before but of course I am paying it more attention now since I am having trouble.
My main question is am I correct in thinking that with the canister lid removed when the key is turned the pump should run till the canister is full since it wont build fuel pressure? I turned the key on probably 10 to 15 times and it did not come close to filling the canister.
My next thing to check is the electrical plugs for corrosion and voltage. I did regulate my compressor down to about 30 psi and blow back to the tank when I removed the inline prefilter and I could hear the fuel bubbling int the tank.
Sorry I was long winded but I wanted to give as much info as possible. Thaks for the help in advance.

 

To fill up the canister is by bumping the starter without starting the engine. Doing this will allow the lift pump to run for 30 seconds and will fill up the canister.

 

Bumping the starter or turning the key on? My wife had to turn on the key three times before fuel even entered the canister. Like I said above, the pump only ran for about a second then quit. Maybe I will try to bump the starter over if nobody else has any input.

 

Yes, turn the key to bump the starter but don't actually start the engine and leave the key in the ON position. Doing so will let the lift pump run to fill up the fuel filter canister. This is standard procedure to refill the canister after changing the fuel filter.

 

Turns out the Fass pump is the problem. Removed it and did the bucket test. It would run smooth for a couple seconds then start a hammering vibration type of thing. ran it through an amp meter and the amp draw would spike to about twenty when it did this. I contacted Fass and they were very helpful. They authorized me to remove the allen screws in the end of the pump and check for an obstruction. Removed the gear and it still did the surging thing so it must be something in the electric motor part. Sent it back to them and waiting on word of what the cause is.

 

WELL, what did Fass do?

 

Sorry for the late response. fass replaced the electric motor part of the pump. They never responded as to what the actual problem was with it but sent it back in a very timely manner.

 

It's a defective motor.

 

I know the motor was defective but would have been interested to know exactly what went bad. By the hammering it would do I would think it was something other than the brushes like maybe one of the magnets was loose. Anyways, I was very happy with their service but would have much rather it not have gone out.

 

Guess it an insulation break down or a short in the windings.