Heading to work last night and the fuel pump died. Then worked again, then died then worked. Now I have to figure out how to install the FASS with out dropping the tank or removing the box. GRRRRR out sid ein the crappy weather.
Time is my biggest issue here along with making my pump from my 03 work on the 05. Off to Cdn Tire to try and find parts.

 

Good luck man, always at the best time eh?

 

the fass well pull fuel thought the stock pump when it's not working but it is hard on the fass sodon't leave it like that for long

 

The fuel tank drops out pretty easy, done it lots of times. I would just do that put in a 1/2in stainless line into the tank, thru the fuel pickup screen. You can completely remove the pump. The draw straw is a nice mod, and I have a completely modded (fuel pump removed) fuel pickup module unit sitting at home, with the draw straw installed. I'm still using my home made kit for the last two years, I just haven't got around to dropping the tank. I also have a few gaser units sitting at home, I just haven't fixed them up for a diesel yet. I found a bunch cheap on ebay.

 

I have a vulcan draw straw already. I was going to install the pump tonight but I changed the fuel filter and am getting some fuel pressure so I am going to limp it till the weekend.

I think I am going to drill out the sending unit instead of the fuel tank. like what you have described. (didn't even think of that)

Anyone know where I can get the fitting for the top of the draw straw locally?

If you have any pics of that sending unit with the draw stray it would be appreciated,

Cheers Derek

 

Mike,
any chance you want to sell one of the fuel canisters? I have a non intank pump type canister now, and would like to use Vulcans "kit" to modify the intank moduel. its susposed to eliminate any 1/4 tank issues

 

Sure can if you want. Its one of those hardest to find part for the diesel, of course you could get one from a local wrecker. Been down the bad fuel issue road myself once or twice. The gaser pot stuff, you will need to modify the pick-up module. There is no fuel line return into the pick-up. Dodge sells all the newer style fuel pick-up parts and it is rebuildable. Rumor is that cummins sells some of the dodge pick-up parts, for the older non-fuel pump units. I just don't know when I will be in Edmonton next. My suction screen at the bottom of the fuel pickup module, plugs up way to often for my liking, so its been long gone for years. I can pull fuel down to very bottom of the tank.

On this trip out east, I watched my fuel pressure drop from 18psi down to 15psi , thankfully I have spare filters with me. I'm glad that I have a incab fuel pressure gauge, it has saved my VP a few times. I just borrowed a bunch of extra parts from work to rig up my gauge.

 

Derek, the draw straw just uses large AN fittings. It can be very easily built from local parts. They put in a large plug/metal fitting into where the pump was, just to seal it up. The older style has a plastic 3/8 tube right to the suction screen. There is also a check valve in the screen, just so the fuel in the basket doesn't completely drain out. The return fuel goes into the fuel basket. This helps to make sure that you get fuel during the lower fuel levels. I've ran with and without using the fuel from the basket. Without using the return fuel, you will experience no fuel pressure under hard braking/acceleration for lower fuel levels. Using the return fuel into the basket, solves that. Currently, my suction screen/check valve has been removed. it still works good.

 

If it will help I have the kit from my air dog. It has all the stuff you will need to retrofit the stock pickup etc. Biggest problem would be that I wouldnt be able to get it to you until next week.

As for getting to the top of the tank, you could do like we did on my truck last year, get a angle grinder and just cut a hole in the box

 

Is your current fuel pump in the tank or externally mounted on the fuel filter cannister?
The external fuel pump is still available from Geno's garage if you don't have time to mount your FASS now.

http://www.genosgarage.com/prodinfo....UMP_FPD4089602

If you have the external pump & you have the regular FASS Pump there is no need to modify the stock fuel pickup cannister. No need to drop the tank.

If you have the in-tank pump, which is mounted in the fuel pickup cannister, it definitely needs to be modified for any external pump.

As Mike said, the tank drops out fairly easily. If your pump is still sorta working, you can drain the tank by opening the water drain, keep bumping the ignition key to make the pump run & pump fuel out the water drain into containers.


...Joe

 

Hose Headquarters have the bulkhead fittings that you need 03. They were the exact same fitting as when I did the drawstraw on my 2001 FASS.

 

The name of the fitting @ the top of the tank is called the Dorman fitting, must be the name of the clown that invented it. There is a couple different sizes. Have a look @ Glaciers diesels site, he has pics of what you will need. That way you can tell the no smart partsman.

 

Hose Headquarters has them cool. I will try to get their tomorrow to pick one up.

I am going to install the FASS this weekend, drop the tank (hopefully it is not raining outside) But I am going to try and leave the factory pump still hooked up. but block the line off by the fuel filter. Last time my FASS failed I just reinstalled the fuze and ran on the stock pump till the FASS was fixed 3weeks later. The stocker is still working but only putting out 5psi. Seems time for the 2 micron filter install also.

I just about cut a hole in the top of the box, but the stocker started to work again. Thanks for the offer on the parts, I will try to source out parts here first.

For a town as big as Red Deer, you sure have to drive all over the place to find even the simplest of parts some times.

It is project fuel tank this weekend, then it is project shoot the SKS at some random targets on some open area in the middle of nowhere. Been meaning to get out the past two weekends shooting but it has not happened, this weekend it will hopefully. Maybe a few water melons with the 12 gauge.

I sure am glad I have a fuel pressure gauge installed though with out one I would have had the truck towed to the dealer to figure out why it stalled out.

 

Update, I need a new fuel module broke the return lone off the one now I got lines running all over the place by passing it. If anyone has one of these ready to go or close to it let me know please,(hint hint Mike)

 

I do have two inside my garage, but I'm in Chicago, sorry buddy. What did you break? I think that the draw straw mod, you drill out the return line anyways at the top of the module and put in a larger fitting. I would do that if its broken. I would put in a 10-12AN fitting (I think the right size, its about 1/2in sized fitting). Some stainless tubing would work as well. You need to put in some flexible hose as the unit moves up/down some. Short of breaking the module in two, you should be able to get it fixed up. I have one 3rd gen unit with the draw straw mod already done, I was going to put it into my truck. I just never got around to it. I found out this week if I get down to very bottom of my tank (when that 100km dash light comes on and you have drove about 80km's) , on hard braking/hard acceleration, I have no fuelpressure. I had to look really hard down here for cheap fuel. The fuel here is pricey, I paided 3.15 per gallon. Today, I found a card lock that sells fuel for 2.85 per gallon, of course after my tank is full. Every where else is 3.35 a gallon, so I just saved $4-5 just on one tank.