97 4x4 2500, 87,000 miles. Hard to start after sitting for any length of time. Replaced all fuel hoses, return, supply, even the short hose between the heater and the lift pump.
Replaced the lift pump (low pressure), replaced the overflow valve (bad spring) and it still is getting air in the lines. It gets worse if it is around 1/2 full, better if pointed uphill.
Matter of fact, I don't DARE let it get below 1/2, afraid it won't start at all. I work 12hr shifts and if I clamp the return fuel hose off ( I made it longer and rerouted it away from
the head) it starts with out priming or cranking the heck out of it but it still
has some air in it. No noticeable fuel leaks anywhere. Mileage hasn't changed and still runs great after it starts and gets the air out of the lines. WHAT AM I MISSING?

 

Sounds like the return hose has a leak in it somewhere. Tighten all the fittings and check all the hoses. I don't think it's a starter problem.

 

No. I know it isn't the starter. It also isn't the shutoff solenoid or the relay.

 

Then it's somewhere in the hoses or fittings.

 

Just took the fuel lines off my 1st gen last night, the fittings the lines attach too at the tank look like cheap plastic. I was worried about damaging them. They seem to swivel meaning there is probably an O-ring involved in there. Just thinking out loud.

 

I don't know on dodges, but is there a "flaired fitting" in the system??? If they are not flaired correctly they will suck air upon shutting off the eng. Just a thought, good luck!

 

Well, after 4 months of looking, I finally found it. While doing an oil change, I decided to check the tank. Crawled up along side the tank and the top was slightly damp with diesel. Wiped everything clean, checked the connection of the plastic lines, everything looked good...............till the next morning. Had to prime it to start it, died twice more. Seems the two metal tubes that bend at 90 degrees and go into the tank had pinholes in them. Of course it was Saturday, so Dodge service/parts department wasn't open. But I grumbled at a salesman enough, he called service manager and they checked to see if they had the part, which of course they didn't. Went to Advanced Auto and bought fuel tank repair kit, cleaned everything, lightly sanded the rust, mixed the epoxy and applied. PROBLEM SOLVED! Truck sat for 24hrs and started right up. Used to be it would sit for 30 minutes and give me a hard time. Thanks to everyone for their suggestions.