Hey Folks...
I have a 1998.5 1-Ton. Approximately 6 months ago I installed an AFE stage II intake system and an Edge Juice w/Attitude monitor. With the ability to monitor the fuel pressure, I have had to be cautious as it has been easy to get into a low fuel pressure situation (below 4 or 5 psi). I saved up and have recently added a FASS 95 HPFP pump. While installing the FASS pump...when removing the quick-disconnect fuel suction line back at the tank pick-up, I noticed that the steel pick-up tube was really rusty. In the process of removing the quick-disconnect, the flexing must have caused the rusty pick-up tube to crack or develop pin-holes in the rust... as now I have a fuel leak there in the 90 degree bend coming out of the fuel tank 'cap' that houses the sending unit.
In the process of trying to find a new pick-up tube, the dealer is telling me I need a whole new fuel tank! I do not believe this, but have not tracked down the replacement part that I do need yet.
This is where I need help.
Moving on, The truck is very hard to start now... is it mainly due to the air allowed into the system? OR do I have the VP44 diaphragm damage and or pump rotor to housing wear problem? The FASS documentation warns of possible hard starting when replacing the lift pump on the 98.5 -02 year trucks due to VP44 damage already done by low fuel pressure. Prior to replacing the lift pump for the FASS unit, I never had one starting issue... EVER, and never had to replace a lift pump. The truck has 150k miles on it. I did have to replace an APPS sensor one time.
I have thrown a lot out there, but need a little guidance from the experts at this point on diagnosing the VP44. Maybe it is just the air in the system at this point. Once I get the truck started, it flutters for a little while, but smooths out for the most part... although it does sputter and rev slightly on it's own, but does not quit. I am going to drop the tank tonight and remove the tank cap and sending unit to see if I can repair the leaking fuel pick-up tube.
Thanks in advance for any assistance.
Ian

 

With air getting into the system you will get a hard start/irratic running condition. I had to replace the sending unit on the tank of my 97. It is pricey and I really hope that they now have a totally plastic unit. The only steel on them is the top of those two lines you mentioned. Good Luck!!

 

DOnt need a new tank...just need one of these or you could go with one of our STK-1001 kits......

 

Thanks guys.
I picked up the STK-1001 kit this afternoon and will hopefully install it tonight and go from there.