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Location: Toronto ontario canada | I have a 2003 Dodge Ram 2500 , 5.9 Cummins diesel that has developed an ennoying problem. When the fuel tank gets down to about half full the truck just quits and when I add fuel it starts and runs like nothing ever happened. Checked for codes but found none, dropped fuel tank and checked pump and hose and all seemed ok. Any Dodge gurus out there that are familiar with this problem. I don't mind spending money and have the problem fixed but I hate wasting money without resolve. |
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Location: Sumas Washington | Sounds kinda weird, Are you sure that the pump is functioning properly? Does it overheat more when the fuel level is low? I would assume that the pump is at fault... MAYBE when the fuel level gets low the pump overheats?? I have installed dozens of FASS aftermarket fuel pump-filter systems, this is the first upgrade I would recommend. These trucks run much better with excess fuel delivered to the common rail pump.. |
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Location: Toronto ontario canada | My mechanic is puzzeled by this too and also suspects the pump may be over heating so when it died today , I let the truck sit for about twenty minuetes hoping that if the pump was over heating it would cool down and start but it did'nt. However after adding five gallons of diesel that i've been carrying in a jerry can and a few cranks,it started . I would be interested in hearing more about the upgrade you mentioned if you would elaborate. |
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Expert
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Location: Vermont | Originally written by sidelock on 2011-06-13 6:45 PM
I have a 2003 Dodge Ram 2500 , 5.9 Cummins diesel that has developed an ennoying problem. When the fuel tank gets down to about half full the truck just quits and when I add fuel it starts and runs like nothing ever happened. Checked for codes but found none, dropped fuel tank and checked pump and hose and all seemed ok. Any Dodge gurus out there that are familiar with this problem. I don't mind spending money and have the problem fixed but I hate wasting money without resolve. When they dropped the tank...did they open it up to see where the fuel pickup was currently residing in the tank? |
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Location: Toronto ontario canada | They told me the unit is spring loaded and sits in the tank under preassure between the top and bottom of the tank with the pump sitting at the bottom. |
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Location: Sumas Washington | I PMed you with more information, The fuel tank basket in the bottom of the tank is quite robust but has shown failure in some high mileage trucks. I assume that this is a pump issue, I assume that the pump draws more amps when the tank is low, I would assume that there may be a issue with the pump to tank wireing, might not be making proper connection when the fuel is low.. ??? |
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Location: Toronto ontario canada | Thanks for your help Robert. We are not sure yet that it is a pump issue . Although they inspected the pick up tube and said it had no cracks or holes, if there is a hairline crack and they missed it, it could be a vacuum issue .They are going to put some sort of relay to have the fuel gauge read 3/4 full and stay there regardless how little fuel is left in the tank to see if the truck will keep running past the half full volume mark. If it does keep running , then its not the pump but some elecrical or sensor issue giving the wrong signal that the tank is empty. I have to enbark on a cross country journey with my dogs and horses to the praries in mid July and I'm hoping they sort it out well before that so I can have some peace of mind while travelling.
Edited by sidelock 2011-06-14 3:15 PM
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Location: Toronto ontario canada | B.T.W. I shoul also mention that the previous owner must have done the pump relocation upgrade because its in the tank not under the hood behind the fuel filter . |
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Extreme Veteran
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Location: Minneapolis, MN | I was recently at FT where a pro's Dodge was having issues. Seems it was the secondary lift pump that was overheating. This pump is mounted below the fuel filter on the drivers side. I think the truck was a '07, so this may not apply to yours. It was said that the preferred dealer fix was to block this pump locations off and move the pump to the tank. But when doing repairs in FT parking lot...dropping the tank didn't make much sense. |
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Location: Gallatin, TN | We had a similar problem with our 99 F250, turned out to be a combination of problems. The fuel gage read 1/2 full when it was close to empty, there was a problem with the float on the level and we got false indications of fuel level. We also have a fuel pick up issue. |
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Location: North Salem, IN | Those trucks are really common for the sending unit for the gauge going bad. Next time it dies, tap on the tank and see if it really is half full or empty. I have had 2 Dodges that had bad sending units. The last one, I put an Air Dog pump system on it. It had 460,000 miles at the time. |
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Location: Toronto ontario canada | Every time it happened it only took 60 or 70 liters of fuel to fill thr tank and the tank's capacity is 128 liters , so it's defenetely not running out of fuel. |
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Location: Sumas Washington | The pump in the tank is located approximately at the 1/3 full mark. The connecting wires are located at top of the pump. It might be possible that when the wires are covered with fuel they make contact and the pump runs. When the fuel level is below the wires the contact is broken and the pump wont run. This may be a stretch but this is the only thing that makes some sense. I would install a aftermarket pump and drive the next 200,000 miles and not worry about it.. |
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Location: Toronto ontario canada | That is my intention ultimately but I want to isolate the problem first and make sure its the pump. Spoke to Mark @ PDR already and he recommended a 95gph pump (# TD08095G ) since my truck is stock without any performance mods. According to their website the 95gph is good for up to 600 HP and they claim it is best not to have more pump (gph rating ) than what is needed for a given application , as the bigger pump will live a shorter life by by-passing more than normal. |
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Location: Sumas Washington | I would tust Mark at PDR, really knows his stuff both on stock to wild Horsepower Dodge Diesel trucks. |
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Location: Toronto ontario canada | Hey Robert, I got a second opinion on the FASS system by another dealer who sells them and I was told that since the original pump in my truck was replaced by an in tank pump, if I were to install an FAAS system the engine may miss or even stall when going around a corner or incline if the fuel in the tank is down to about one quarter full or less because there is no baffle. Needless to sy this could be dangerous especially towing horses. Have you ever heard or experienced such occurence ?
Edited by sidelock 2011-06-18 7:47 PM
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Extreme Veteran
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Location: Claxton, Ga. | Put a fuel pressure gauge on it so you can see exactly what it is doing. With the intank pump you should have from 8-10 PSI of pressure at idle after the filter and before the CP3. I run an Airdog setup. You can run that with no issues but to get the draw straw cut to the proper length it is best to take the bed off the truck and install it while the tank is still in the truck. I have also connected my Airdog up to the back of the factory filter for a last chance filter. You will need the o-ring given plus one of the factory orings that is on the banjo fitting. |
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Location: Toronto ontario canada | This is getting too complicated. I just ordered an OEM in tank pump and will be replacing it on Thursday. Keeping my fingers crossed that it is the pump that needs replacing. |
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Location: Sumas Washington | Sounds like you made a good choice, the stock in tank pump really does OK in most situations. It would be nice to have a fuel pressure gauge so you could check on things. The FASS pumps installed as the instructions say, do have the problem you described. Mark at PDR has been using another method for fuel pickup and it works great. I have installed 6-7 in tanks replacing the stock pump, and have had no complaints. It is all about the installer and your relationship with him.. |
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Location: Toronto ontario canada | Had the mechanic pull the tank and replace the fuel pump and it's still doing the same thing. $800 down the drain ! |
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Extreme Veteran
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Location: Claxton, Ga. | Check the wires at the relay that was probably tie strapped somewhere on the drivers side battery area that runs the retrofit intank fuel pump and replace the fuel filter if you haven't already. I would also check the fuel sender. If you drop the tank when this happens does it have a half a tank? This issue is fixable. Find a new mechanic.
Edited by Spooler 2011-06-23 8:50 PM
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Location: Toronto ontario canada | I have'nt replaced the filter but the first time it died , the filter only had approx 600 miles. If it is a filter issue, why would it only happen when the fuel level reaches just below the half way mark ? As I mentioned before, every time it dies and I top the tank up, it only takes about 70 liters and the tank capacity is approx 130 liters. This is happening at a specific fuel level every time, just a little below half full. Every mechanic and dealership I asked about it has never dealt or even heard of such issue. |
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Location: Vermont | When this happens does the low fuel light come on? |
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Location: Toronto ontario canada | No the low fuel light warning does'nt come on. The truck just dies suddenly as if someone turned the key off.
Edited by sidelock 2011-06-25 7:19 PM
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Location: Vermont | Originally written by sidelock on 2011-06-25 7:17 PM
No the low fuel light warning does'nt come on. The truck just dies suddenly as if someone turned the key off.
Did they check the fuel sending unit?...Because Dodge had a problem with them and diesel fuel...
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Location: Toronto ontario canada | I thought the sending unit is an integrated part of the intank fuel pump that I just had replaced. |
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Location: Toronto ontario canada | I thought the sending unit is an integrated part of the intank fuel pump that I just had replaced. |
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Extreme Veteran
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Location: Minneapolis, MN | Did the fuel pick-up get changed with the pump? The reason I ask is that the Ford has a by-pass on the pick-up, maybe 3-4" from the bottom of the pick-up...that allows the pick-to still draw fuel, if as in a near gel situation, the pick-up screen gets clogged. |
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Location: Vermont | Originally written by sidelock on 2011-06-26 7:52 AMI thought the sending unit is an integrated part of the intank fuel pump that I just had replaced. You need to confirm with your mechanic if he did replace just the fuel pump and reuse the old sending unit or did they put in a complete new module... You should post your problem over on a site like this... http://www.cumminsforum.com/
Edited by PaulChristenson 2011-06-26 8:36 PM
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Location: high desert, CA. | I agree with the other poster. Look to the guys at www.cumminsforum.com. Most of those guys have either seen this before, or can send you to a TSB or fix. You can also do a search of the forum and get what other guys have fixed problems with.Steve
Edited by siseley 2011-06-26 8:50 PM
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Location: Toronto ontario canada | The mechanic replaced the whole module and I did post on other the web sites including cummins. The big mystery in this particular case is why is it happening only when the fuel level get down below half full. |
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Dodge Ram
