wallypedal

Posted this in 3rd Gen too. Need to get back to Wyo for wife's doctor appt..
I have a 2004.5 that quit on me late yesterday in Nebraska. I've read the lift pump posts enough times I'm convinced that is what is wrong. Truck sputtered and died, drained the filter, ran sputtered and died, less to drain from the filter. Pulled the filter, filter housing empty. Towed to a dealer, left it outside, now at my daughter's house 15 miles away. Didn't remember the Pcode check procedure.
I read up some more last night.
- can anyone verify for me without looking that this truck has the external pump? I've had it since new, definitely 2004.5 with the larger exhaust introduced then.
- it looks like Geno's and Summit have the Carter Federal Mogul replacement pump - is that the way to go? Does anyone have part #'s? I have no big mods, just pull my boat and camper around in the summer.
- is it true the dealers don't replace the external pump, but insist on the in-tank replacement now?

I need to get this moving, who can I get parts from that really does expedite shipping the best?

I have a place where I can work on this, and decent tools and mech skills...

OR, should I just tell the dealer to fix it I don't think I've done that with anything ever.....
Any advice appreciated, I'm kinda stressed and not sure what to do.
Wallypedal

patdaly

If it is a 2004.5 you have an in tank pump.

Sorry, can't help much past that.

wallypedal

some sources say it might be external. I'm wanting to order something, but can't order the right stuff without knowing in-tank vs. external for sure. Will just get over there and verify.

Dr.Dizzle

The 03-04.5 trucks come factory equipped with the fuel filter housing mounted lift pump. The 05 trucks were first equipped with the "in tank" design.

If you want the least expensive pump that will take little time to install, then go with a direct replacement pump from Genos:Item Number: PUMP_FPD4089602. Ask if they will expedite shipping. This is a very straightforward replacement. Just keep in mind that this type of pump is a weak link on the 03 to 04.5 MY and may require replacement in the future.

No need to get the dealer involved in this.

Dr.Dizzle

You will need an allen wrench in order to remove the four socket head cap screws that hold the lift pump to the filter housing. Allen wrench sockets and a ratchet work the best for this. Be sure to remove the old o-ring from the housing after removing the pump.

patdaly

Thanks for correcting me. Can't remember where I got my info from, but I was incorrect.

To the OP, don't change it to the intank setup. They fail as well, just not quite as often.

There are better, cheaper aftermarket setups.

wallypedal

OK, guys, and thanks! Patdaly, I did check and it is external mounted. Thanks also for confirming the correct info - I don't think I have ever seen anyone do that on any forum! Found one at a local NAPA, so we're almost back running. Pricey compared with Geno's but available right here.

Lary Ellis (Top)

Actually I have come across a handful of 04.5 trucks with the in tank pump even though the owners claim they were not retro-fitted at a later date.

But of course nothing surprises me any more on the way they put these trucks together at mid year model change.

Dr.Dizzle

It's certainly possible that they slipped some in during production and does not surprise me at all.

Dr.Dizzle

wallypedal,

Now would also be a good time to purchase a fuel pressure gauge and additional fuel filtration to complement the canister filter. I recommend you check out the DTR store and contact Lary for a gauge and a GDP 2um filter assembly in order to extend the life of the injectors.

NE frmhnd

It's nothing new. When IHC switched over from the M to the Super M, they just added the newer parts to the supply line and whenever they ran out of the old part the new one finally made it onto the tractors.

Sounds like they didn't quite have enough of the old part in the que so they just stuck the new one in.

Gotta love Nebraskan NAPA stores. They even keep lift pumps for my truck on the shelf.

Gatorama

The biggest problem with the old "non-tank" lift pump is they are the first place in the fuel delivery system that can collect water. Over time, enough will settle in the bottom of the pump to take out the pump motor lower bearing, usually indicated by an ever louder whine from the pump. Bad design on the part of Dodge, or a plot to sell more pumps. I installed a drainable filter/water separator between the tank and pump on my old '00 and never had any more problems.

chaikwa

Stick around. You'll see that I'M wrong most of the time!

Totallyrad

My 04.5 had the block mounted, mechanical pump. Mine went out at 79k and was replaced under warranty. The part that I can't remember for certain is whether they used the Cummins emission warranty or the extended warranty I purchased. I'm thinking it was under the emissions warranty. The conversion kit was between $300-$400.