My name is Dennis x3 (x3 represent that I own a 90, 98.5 and a 2007(6.7) Dodge Cummins) and I purchased a PowerPack system from Banks around 2001. Shortly after I installed it I was getting on it (pushing it) and right around 2700 RPMs and 30 + on the boost the check engine light came on and the engine died. Dodge replaces that injector pump and lift pump under warrantee (67K miles). It that time I became cautious about getting on it but time passes (about 2 years) and I did it again on the same road in the same part of the road and again I got on it and again it failed. This time I had to pay for the pump. There was no lift pump failure at this time.
So to avoid this again I put in a FASS fuel system and I have a pressure gauge installed on the right hand pillar with turbo boost and exhaust temp gauges. I also replace the injector pump just in case of a potential weakness that might have accrued before I replaced the fuel pump. At that time I explained to the wife (main driver) not to take it over 2700 RPM and so things worked for some time.
About 5 years ago I developed a strange dropping out the Banks system and I ordered a new Auttomind. I replace the Auttomind but the problem turned out to be some type of buildup on the exhaust temperature sensor and once I clean that off all was well.
About a year ago I started getting an occasional dropping of the Banks system again. So I check the wiring and all seam good I went to replace the Auttomind but when I went to plug it in one of the connecters (3 pin) broke off. I sent the unit back for repaire and after 5 mounts I got it back.
Last year my wife was in Canada with a trailer full of horses and the pump failed again. The pump was around 2.5 years old and during that time we never pushed it so to speak and always kept it under 2700 RMS with maximum acceleration. But also over the last 18 months the Banks would drop in and out at random. I call your tech support about this and they suggested possibility a wiring issue. I check it and redid it several times with some reliability improvements.
Two week ago we went to get 6 tons of hay and bring it back from eastern Washington, we live in western Washington. Only a few mountains to go over and the Bank would not go over 25 lbs. pressure, this is not normal. So I had the repaired Auttomind available and I put in on Saturday March 1 2008.
When done, I took the truck for a test drive and the Banks was back. Great I was thinking. But during my test drive I got it up to 35 LBS of pressure and 2600 or 2700 RPM and blew out the injector pump again.
The truck just turned 200K and we had about 10K mile or less on the current injector pump. At no time did the fuel pressure gauge ever go less than 10lbs ever.
4 pumps and 3 Auttominders and I still have the problem I had 140K miles ago and it keeps getting more expensive financially as well as this issues with my wife. I think we all understand the wife issue.
I recently got a 6.7 and was looking to get some performance upgrades and with the support I have recently received from Bank’s on this issue I would not get anything from banks this is electrical related and it would be questionable why I would get Banks anything.
I am an IT tech and have worked on computer for 30 plus years. I understand troubleshooting but this one beats all. There is something majorly wrong but I cannot figure it out.
Oh ya, if I take the wired off the injector pump I never have an issue with any hastening, only poor (normal)performance.
So I down to removing the Auttomind but I still need more power.
So what I need to know is the best way to resolve my issue. Get a different injector pump? Injectors? Stay with Banks? HELP. I really want to solve the failing injector pump problem once and for all if possible.
Last item is Bank’s is no help at all on this issue and says it not there problem. I do not know how it is not a Banks issue with all the different parts that have been replace or updated and it still predictably fails.

Thank you for listing.

 

Welcome to world of equipment manufactures not being responsible for their lack of engineering.
First thing throw the banks stuff as far from truck as possible. Learn up on other systems and buy and be done with the night mare. Maybe not so agressive(less apt to damage engine/components) components will jump out and say buy me.

 

.....and leave your 6.7 ALONE!!

 

The odds of all those injection pumps being bad is very poor. The odds of the Banks Ottomind modules being bad on a 24V truck is very high. I can see one of the pumps being bad originally, but getting on the throttle and letting off abruptly on a 24V with upgraded power sometimes causes them to stall or act weird, especially if you have bigger than stock injectors. Throw out the Banks module and get something different, preferably one that does not tap the pump wire (like an EZ or a downloader), and make **** sure something is bad before throwing parts at it. What was wrong with the injection pumps? Did they give the timing error code? Did you try cranking the engine and bleeding the injection lines?
As far as your 6.7L, leave it alone until it it out of warranty, or give the aftermarket a year or so to sort out the issues with more power/fuel and the DPF.