No Start Loosing Prime ....long Time Problem 6 Months + This Time It Wont Start At All And I Have A Air/fuel Leak Top Side Of Fueltank Where Lines Go In. Not Line Leak Must Be Gasket In Between? What Is The Best Way To Fix? Where To Buy Parts? Good Time To Up Grade?
98.5 Dodge 5.9

 

assuming you have already tested for fuel pressure at the VP44, i would check for codes with a scanner, if you have none then pressurise the fuel tank with 3 or 4 psi air and look for leaks...... if the gasket is bad , it will not cause a hard or no start condition....but if your tank isn't full and the draw tube has a leak in it you will suck air....... by putting air pressure in the tank if the "draw straw" has a leak you will get air at the filter

 

by the way , a canister type vacuum with the hose reversed will probably work for air pressure

 

Bet your tank module lines are rotted off.

Best course of action is to put a stock Vulcan Draw Straw in.

Done it to too many already. Feel around the tank to module lines, see if you can feel scale.

 

If Lines Comming Out Top Of Tank Are The Same Lines Then Yes There Is Scale But With Key On I Can See Fuel Bubbling Out Top Of Where Lines Go In To Tank So There Is A Gasket There???? That Would Seal That Off??also I Pulled Line Off Lift Pump Before Injection Pump And Got Good Pressure But When I Loosen Injector Lines At Injector And Bump The Key To Start Injector Pump I Only See Very Few Bubbles On Two Of The Three I Opened Not Much Fuel At All..so I Pulled The Line Off Before Injector Pump Again Turned Key Off And On This Time I Had No Pressure Before Injector Pump. Like It Let All The Fuel Go Back To The Tank ...
Also A Side Note When Truck Was Running And I Went To Fuel It Up It Would Alwayse Make A Hissing Sound When Taking Cap Off Like Tank Was Under A Strong Vac.. Would That Be Normal

 

there shouldn't be any pressure or vacuum in the tank at any time. check the the vent to see if it's clear. it's located to the rear of the module.....you will not get any pressure in the injector lines between the injector pump and the engine unless the engine is running or cranking to start.......bumping the starter will activate the lift pump for about 30 seconds

 

If you mean right by where the lines go into the tank, then they are rotted. If the fuel is around the outside of the ring, perhaps it could be the O-ring, but I have never seen one go bad. I am betting yours is the same as the 99 and 98 I just did.

Either raise the bed up or drop the tank to find out what you are dealing with here.

And sometimes mine does hiss and other times not, I don't know that has much to show.

 

The metal fuel lines rot at the top of the pickup module and between the tank and frame. Best bet is to replace with good quality hydraulic / diesel fuel hose all the way to the front. You can make a splice with a couple unions in a pinch.
The draw straw is a good idea. I didnt like the way the hose just hung down into the bottom of the pickup unit instead of clamping onto the fitting so I found a small section of nylon tubing and heated it into a coil like the stock unit and clamped it in place. You can also get tubing thats shaped sort of like a collapsable drinking straw that bends better.
The bottom of the sender is set up in such a way that if you bypass the pickup tube you might lose the suction effect.

 

Not true. The tank vent and fuel cap are designed to hold 3 psi of vacuum or pressure.
A hiss is totally normal.

 

well i used a vaccum to blow pressure into the tank and found my leak it blew a hole in the fuel line 1/8" dia no fuel getting up front now i will need to drop tank and replace lines not sure what way to go with that yet lot of ideas coming from you guys stock or other thank you all for the help

 

You don't have to use the stock quick connects a hose clamp will work on the module tubing.
The stock fuel supply and returns on these trucks are so failure prone, even the steel parts, that I never replace just the short hoses.
Just replace the stock lines all the way from tank to engine with good hose and be done with it.

 

what i'm saying is your lift pump will not suck against a vacuum and do good job.......... my tank does not ever have a vacuum or pressure.
i don't think my tank is any different from thousands of other dodges out there

 

here's a post in the 24 valve 2nd gen section
" emoryemt-i
Registered User

Join Date: Feb 2006
Location: Richlands, North Carolina
Posts: 150
i know this sounds crazy bu take your fuel cap off and if it hisses when you do then put it back on but don't tighten it down just let it sit there. i had the same problem with mine, i did this and it fixed the problem. I also replaced the banjo check valve on the side of the vp-44 it was a 30$ part that did not fix the problem but some guys reported it fixing theirs. basically you either have a small leak in your fuel system and you gotta try different things to find it. like i said before, mine was caused by a faulty fuel cap that was causing a vaccum to form in the tank and pull the fuel away from the vp-44 when not running causing the hard start. good luck."

 

is there any place to buy stock steel lines to replace bad ones from sending unit to fuelline?or do they replace sending units to replace this rotting problem $380.00 dealer for new sending unit....

 

jingersoll, just get a Vulcan draw straw, just north of 60 bucks shipped.

Nice setup and it replaces the rotted lines nicely.