Help!

2004 Dodge 3500 4wd, 136,xxx miles, auto, K&N air filter and intake, straight thru exhaust, FASS lift pump, add on water separator after FASS, and Bully Dog plug in programmer set on “tow”. Usually use Lucas, Standyne, or Power Service additive.

Never had any real issues with the motor until yesterday. Pulling empty gooseneck trailer, rolled up to stoplight, and felt like the motor had high idle. 10 seconds with foot on brake, the tone of the motor changed and started rolling black smoke. Didn’t know what to do, so I put in neutral, and RPM jumps to 1500 rpm and then immediately comes back down.

Went down the road ok (a little more smoke than usual), idles in park and neutral ok, but in any gear with foot on brake after about 10 seconds equal same problem as above.
No codes other than one Bully dog says (PE062ecm?) will show up- means nothing according to them. Cleaned out that code & put back to stock-same issues and no codes. Do not see fuel in oil (not a significant amount/no growing).

Any ideas? Thanks in advance!

What is “average” life expectancy for injectors?

 

Welcome. Could be a sticking FCA (fuel control actuator) on the CP3 injection pump. You could try some 2 stroke oil in a tank of fuel (TC-3 ashless) to see if it unsticks. Not a real $$ part or that hard to replace either. Or maybe a bad throttle position sensor. IF you just have an extra water separator and no additional fuel filtration you might have some tired worn injectors but doesnt sound like the symptoms. Get a 2mic fuel filter and ditch that K&N air filter.

 

Is the FCA easy to replace-do you have to have specialized tools, or just unplug it?

If the TPS was bad, would it throw a code?

 

(3) 25mm Torx screws on back of CP3 pump AKA (Injector Pump) use a 1/4 inch drive ratchet and a small extension on the end of the ratchet. Make sure you have the bit up in the screwhead good and break it loose not a hard job. make sure you take off the wire connector first then break them loose. Part cost about $115. I think the part is to high if you ask me but everything on these Diesel engines are high. I guess if you can afford a Diesel truck then you gotta pay high dollar for the parts.

 

None of the local parts stores know what this is, and Dodge dealer says this is part of the pump-not serviced seperately. Is this a Cummins part, or do I have to go to an authorized pump repair shop? Also went to the auto parts store, and they have "low ash" but no "ashless" tc-3 oil. Same thing?

 

Dodge tells you it's a non-serviceable part because they want you to purchase the whole $1000 pump. Find a local authorized Cummins dealer....they have them. Also, www.genosgarage.com has them.

 

Thanks for the help.

 

Update to my issue from earlier post: sprage (sp) in torque converter messed up. Updated to Goerend billet input shaft, 3 disk t.q. and valve body. Works like a champ-ought to for what it cost!

Thanks for the insight.

 

Glad you got it fixed. The FCA would have been tons cheaper than a full tranny for sure but now that you've got that fixed you have room to grow.