Calling all diesel guys!

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ChargedDart75

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Well the time has come. The lift pump on my '05 Cummins has failed. I don't really want to go back with a stock in-tank pump, so I've been looking at the Fass 100 GPH pump (been reading over some other forums, most say to stay away from stock pumps). Truck is stock except for the exhaust. It won't ever have a bigger turbo or injectors because it serves me well for what I need. With that being said, what are your thoughts?
 
I put one in my 98.5 after about 6 Carter ones (got real good at replacing them). Pressure never budged from 15 psi with 100hp injectors and PowerMax3. Still going strong after 7 years and it lives with my buddy in Idaho!
 
I put one in my 98.5 after about 6 Carter ones (got real good at replacing them). Pressure never budged from 15 psi with 100hp injectors and PowerMax3. Still going strong after 7 years and it lives with my buddy in Idaho!
Good to hear. I also think an added bonus is better filtration, especially for these high pressure injectors.
 
Well the time has come. The lift pump on my '05 Cummins has failed. I don't really want to go back with a stock in-tank pump, so I've been looking at the Fass 100 GPH pump (been reading over some other forums, most say to stay away from stock pumps). Truck is stock except for the exhaust. It won't ever have a bigger turbo or injectors because it serves me well for what I need. With that being said, what are your thoughts?
I ran the FASS 95 GPH system on my 99 cummins for 278,000 miles including a ton of sled pulling. Held steady at 17 PSI with 200 hp injectors and dual programmers. Sled pulls, drag and dyno days

the 100 gph later replaced the 95 but it’s just as good.

currently the 05 has the Airdog system on it and it does good as well. Either of those two systems would be what I’d run.

another option is the stand alone pumps, no filters. The Raptor pump(made by Airdog) and the FASS stand alone units both work well. The raptor I feel installs a bit easier with no drilling. The FASS is a bit louder but doesn’t seem as affected by WOT. The Raptor will drop 2-3 psi under WOT, the FASS seems to hold steady. That said, both are a MASSIVE improvement over the stock.
 
I put one in my 98.5 after about 6 Carter ones (got real good at replacing them). Pressure never budged from 15 psi with 100hp injectors and PowerMax3. Still going strong after 7 years and it lives with my buddy in Idaho!
I worked for a couple years for TST, Mark the owner, was on the engineering team for the ISB program and knows his ****. You would not believe the level of engineering into those boxes. The PowerMax3 Comp was the king of its day until timing and EFI live came out for the CRs. I still run a PM3 in my 99, though I had Mark take the Comp tune out. Just too aggressive for the 2nd 99 which was the tow rig. Probably have it put back in now that it’s gone the way of toy vs hauler.
 
Good to hear. I also think an added bonus is better filtration, especially for these high pressure injectors.

I just had the pump, but there was one of those generic metal round filters that was added before the pump to filter the fuel from the tank to protect the pump.

I worked for a couple years for TST, Mark the owner, was on the engineering team for the ISB program and knows his ****. You would not believe the level of engineering into those boxes. The PowerMax3 Comp was the king of its day until timing and EFI live came out for the CRs. I still run a PM3 in my 99, though I had Mark take the Comp tune out. Just too aggressive for the 2nd 99 which was the tow rig. Probably have it put back in now that it’s gone the way of toy vs hauler.

Yeah Mark is a good guy, talked with him quite a bit back in the day, think the last time I talked to him was around 2015 or 2016. I started with a PM2 when they first came out then upgraded to the PM3 with remote when it came out. Mark was the first person who's box actually fueled based on boost pressure, all the other guys just boosted the fueling a set amount. Twenty years later both boxes are still running strong, that says something about the engineering behind them! His PM3 was stronger than my NV4500! Lol
 
I just had the pump, but there was one of those generic metal round filters that was added before the pump to filter the fuel from the tank to protect the pump.



Yeah Mark is a good guy, talked with him quite a bit back in the day, think the last time I talked to him was around 2015 or 2016. I started with a PM2 when they first came out then upgraded to the PM3 with remote when it came out. Mark was the first person who's box actually fueled based on boost pressure, all the other guys just boosted the fueling a set amount. Twenty years later both boxes are still running strong, that says something about the engineering behind them! His PM3 was stronger than my NV4500! Lol

Each box is hand built too. Every chip, every wire, manually put in with hand tools and soldering gun.
 
Each box is hand built too. Every chip, every wire, manually put in with hand tools and soldering gun.
Yeah, Mark's boxes were well built! I remember back in 2014, or so, I thought there was a problem with my PM3 and gave Mark a call. He said to send it in and he would put it on your guys test fixture and see what's up. He ran it for 24 hours on full power and it was fine, as to be expected! He never charged me anything for it and the problem wound up being my solder joint on the pump wire had fractured and would sometimes cause glitches. At the time this box was probably 15 years old and he tested it for free, that's the kind of guy Mark is.

OP sorry for the derailment, just nice chatting with someone who knows Mark.
 
My pump gave up last August just before a road trip to Washington. The pumped worked however started leaking at the mounting point. Since I got 300k out of that pump I stuck with the stocker. However I’m thinking of putting a separate remote pump tied to a switch in case the in tank fails again.
 
My pump gave up last August just before a road trip to Washington. The pumped worked however started leaking at the mounting point. Since I got 300k out of that pump I stuck with the stocker. However I’m thinking of putting a separate remote pump tied to a switch in case the in tank fails again.
What year truck and what engine?
 
My pump gave up last August just before a road trip to Washington. The pumped worked however started leaking at the mounting point. Since I got 300k out of that pump I stuck with the stocker. However I’m thinking of putting a separate remote pump tied to a switch in case the in tank fails again.
The Fass I'm looking at requires it's own suction line to be drilled and fitted in the tank, so you may be looking at doing a different setup than I am.
 
The Fass I'm looking at requires it's own suction line to be drilled and fitted in the tank, so you may be looking at doing a different setup than I am.
That’s why I asked what year. In later years they went to an intake pump trying to solve the lift pump issues.

As for the draw straw, it’s an easy thing to do. I’ve found that pulling the bed is easier and safer to do than dropping the tank. Get the tank as empty as possible, remove the sending unit, then use an old cool whip container inside the tank to catch any shavings. Drill the hole, then put 4 quarters stacked up flat on each other in the bottom of the tank directly beneath the hole you just drilled. Put the draw straw tube ontop of the quarters, mark the height so you know how much to cut, cut it down, test fit again.

all done in an hour or so.
 
What year truck and what engine?

I was wondering the same thing? My Dodge diesel is an 04, which should be about the same as the OP's truck. Isn't the lift pump for those up at the engine, right at the fuel filter? I read that somewhere, but may have misunderstood what the writer meant. Mine is bone stock with 125K miles on it, and never a seconds trouble.
 
Yep, the lift pump trucks are up at the fuel filter and have to pull fuel from the tank. Later they shifted to in tank pumps that pushed to the fuel filter.

I pulled apart my lift pumps that failed and they all had the same problem. The vanes that slid out during rotation to pull the fuel would wear and get cocked in the pump hub that spun them. You would first see pressure fluctuations, then eventually they would wear so much that they wouldn’t extend anymore and catch the fuel.
 
I was wondering the same thing? My Dodge diesel is an 04, which should be about the same as the OP's truck. Isn't the lift pump for those up at the engine, right at the fuel filter? I read that somewhere, but may have misunderstood what the writer meant. Mine is bone stock with 125K miles on it, and never a seconds trouble.

Yep, the lift pump trucks are up at the fuel filter and have to pull fuel from the tank. Later they shifted to in tank pumps that pushed to the fuel filter.

I pulled apart my lift pumps that failed and they all had the same problem. The vanes that slid out during rotation to pull the fuel would wear and get cocked in the pump hub that spun them. You would first see pressure fluctuations, then eventually they would wear so much that they wouldn’t extend anymore and catch the fuel.

normally, yes they are up on the engine from the factory.

HOWEVER, in some cases, there were some that got an in tank pump. There was no rhyme or reason really. Started in late 2000 thru about 06. It was completely random, I think it was done namely as a trial to see if they lasted longer than the original design.

also, if you had a Vp44 go out and be replaced under warranty, at one point, there was a service bulletin requiring warranty replacements to swap the sending unit for one with an intank pump. This is how my current 99 got an intake pump. There’s actually 5 different sending unit/pump/no pump combinations.
 
I'm almost positive this one is in tank. There is no pump beside of the filter. I also thought all CP3 pump engines had the pumps in tank, unless it was an early CP3 engine.
 
I'm almost positive this one is in tank. There is no pump beside of the filter. I also thought all CP3 pump engines had the pumps in tank, unless it was an early CP3 engine.
Depends. I really think they just grabbed what they had lol. I’ve worked in an 09 6.7 liter with a lift pump on the block.
 
Depends. I really think they just grabbed what they had lol. I’ve worked in an 09 6.7 liter with a lift pump on the block.
Learn something new everyday. I just went out to check and see if the pump was for sure in the tank and for the heck of it bumped it over and the dang pump started running. First time in months that I've heard it, but I still think it's on it's last leg at 265k.
 
Depends. I really think they just grabbed what they had lol. I’ve worked in an 09 6.7 liter with a lift pump on the block.
I have another question for you pertaining to this '05 truck. The CP3 pump has a weep between the two halves at colder temps. I have read that the bolts can back out and just need to be retorqued. Do you think the seals are actually bad or could it be those little torxs head bolts can back off?
 
I have another question for you pertaining to this '05 truck. The CP3 pump has a weep between the two halves at colder temps. I have read that the bolts can back out and just need to be retorqued. Do you think the seals are actually bad or could it be those little torxs head bolts can back off?
I have seen both happen. What we always did when one came in with that issue was retorque to spec and check to see if it leaked afterwards. Plus it’s free to check that. We didn’t even charge for that step if that solved the problem cause it didn’t take long at all, half the time it was done in the driveway.
 
I have seen both happen. What we always did when one came in with that issue was retorque to spec and check to see if it leaked afterwards. Plus it’s free to check that. We didn’t even charge for that step if that solved the problem cause it didn’t take long at all, half the time it was done in the driveway.
I think that's what I'm going to try first. I'm fixing to order the pump so the truck will be getting it all done at once. Hopefully that will fix the weep.
 
Well I wanted to wrap up this thread. I order a Fass Titanium 100GPH pump. Fass has actually changed their suction side to where you now modify the factory fuel pump assembly instead of drilling a hole in the tank. Honestly it was a bit more work and pretty tedious, but I liked this better so if I ever wanted to go back stock (not going to happen), I could swap assemblies and go. Also, this new pump is so quiet compared to any other Fass I've ever heard. You can barely hear it when it's priming, but it's definitely working. What took so long was I order a CP3 pump since my stock one was junk and it took forever to get here, but the truck runs great and I am very pleased.
 
Well I wanted to wrap up this thread. I order a Fass Titanium 100GPH pump. Fass has actually changed their suction side to where you now modify the factory fuel pump assembly instead of drilling a hole in the tank. Honestly it was a bit more work and pretty tedious, but I liked this better so if I ever wanted to go back stock (not going to happen), I could swap assemblies and go. Also, this new pump is so quiet compared to any other Fass I've ever heard. You can barely hear it when it's priming, but it's definitely working. What took so long was I order a CP3 pump since my stock one was junk and it took forever to get here, but the truck runs great and I am very pleased.
I changed to an external pump with a Draw Straw in my old truck and found that it wouldn’t draw the fuel out of the tank once it reached 1/8 full. Later I bought the kit that bypassed the in tank pump in order to utilize the stock pickup and I could then have access to the last 1/8th of fuel. That being said you made a good choice in your fix.
 
An 09’ doesn’t have a block mounted lift pump, that is the fuel filter, if factory.
 
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