closetredneck
New Member
I started a thread over at the other "place" looking for some advice on issues I was having with my new to me 1996 K1500 reg cab. Short story, after running for about 30 mins, the truck would lose power, run rough, and wouldn't go over about 25 mph. Seemed fuel starved. It died on me once, was hard to start, but started again after 5 mins or so. Did this every time I took it out, though it never stalled again. Got it home and parked it and checked the tank. I did notice a slight "whoosh" sound when I removed the (new) diesel fuel cap and could hear the tank expand. Fuel filter was recently changed and relatively clean, but a little orange. The next morning I checked the LP operation - could hear the pump kick on at key on and after a cold start I had fuel at the water drain valve at idle. Took it out for a ride and same thing happened. When I got home was idling rough and surging. Checked fuel at water drain and nothing - engine promptly died. Had to bleed and prime, truck started again but died within ten seconds. Bleed again, prime again, spurt fuel all over FFM and down in valley. Go to crank, nothing. Either the excessive cranking or the fuel mess took out my weak and dying starter. Replaced starter (went with a powermaster hi-torque gear reduction model), now the engine fires up like a champ. Back to the fuel problem. Suspecting plugged tank sock or weak lift pump or both. Sending unit and lift pump were both replaced in late 2011 with aftermarket parts. Blow air into line from lift pump inlet back into tank. Took it for a ride and ran a lot better, but still low power at highway speeds / WOT.
After doing a lot of research on here and the "place", decide to drop the tank and do a "4thesporty" type feed the beast mod - remove sock, install pre-pump filter, Walbro FRC-10, delete FFM & replace with another spin on, and run all new braided stainless line to IP. I got in touch with Leroy and ordered up the pre filter kit, Walbro, and metrum rod, along with a new bumper mount PMD kit (PMD is currently on a sink on DS fender), boost fitting, and S&B air box. Installed gauges while I was waiting for fuel line parts - Boost, EGT, & fuel pres. Also replaced the rusted out transmission cross member and trans mount. Dropped the tank and found a well defined rust line about 1/2 down and running fingers around sending unit opening and top of tank felt a bit like sandpaper and left orange slime on my fingertips. Plus, looked like coating was flaking off walls. Decided to replace tank, went with Spectra premium - $105 shipped from Amazon.
While waiting for parts, I installed DE exhaust with no muffler (Sorry Leroy - had already ordered before I found you!), heath x-over pipe, new CDR valve, I modified the sending unit with the metrum rod - that was cool - and re-installed the sending unit. Also replaced all but one battery cable & the starter cable and replaced the broken trans dipstick tube. While the tank was out, did some rust cleanup & painting on the frame crossmembers where the tank goes. Also, had to figure out where to put all this new stuff on my reg cab long bed 4x4. Not much room under the cab with the xfer case, torsion bars, xmembers, etc. Felt my only options were pass side frame rail near exhaust or outside of DS frame rail under cab. Decided, reluctantly, to go on outside DS frame rail - not my favorite because you can see it and the thought of someone f'ing with it is a concern. Also had to clear the p-brake cable and brackets, so fabbed up some boxes out of 1/8" x 1" angle to mount/protect all this stuff. Drilled the sides of the angle in case I decide to install covers later. Anyway, got all my AN fittings, braided PFTE hose and everything on hand and tackled that job this weekend. Also removed the IP fitting and drilled out the holes to 5/32" and then chamfered the edges. Added a Walking-J AN fitting and popped it back into the IP. Got everything mounted, plumbed, wired, and primed yesterday and she started right up. Only one little leak where I forgot to tighten a fitting all the way. New Fuel Pres gauge is showing 14-15psi at idle with only a slight drop to about 11-12psi when I give it throttle. Let it run for about 10 mins then turned it off to install the new air box. Didn't have time to do a test ride last night to see if my problems are cured - I want to do one final safety check on a fresh head to make sure everything is tight and all wires & lines are secured. Have to say though, that Walbro pump is LOUD!! I'll try to post up some pictures of my setup later on.
So this may be a little premature since I don't know if my problem is fixed, but I just want to say thanks to everyone here for the vast amount of knowledge, helpful tips, informative posts, and excellent how-to's and lessons learned from previous fixes and upgrades. Between here & the place I feel like I can tackle almost anything on this truck. Also want to thank Leroy for his assistance and great parts at great prices. Also, 4thesporty for the inspiration and guidance on the fuel line upgrade.
After doing a lot of research on here and the "place", decide to drop the tank and do a "4thesporty" type feed the beast mod - remove sock, install pre-pump filter, Walbro FRC-10, delete FFM & replace with another spin on, and run all new braided stainless line to IP. I got in touch with Leroy and ordered up the pre filter kit, Walbro, and metrum rod, along with a new bumper mount PMD kit (PMD is currently on a sink on DS fender), boost fitting, and S&B air box. Installed gauges while I was waiting for fuel line parts - Boost, EGT, & fuel pres. Also replaced the rusted out transmission cross member and trans mount. Dropped the tank and found a well defined rust line about 1/2 down and running fingers around sending unit opening and top of tank felt a bit like sandpaper and left orange slime on my fingertips. Plus, looked like coating was flaking off walls. Decided to replace tank, went with Spectra premium - $105 shipped from Amazon.
While waiting for parts, I installed DE exhaust with no muffler (Sorry Leroy - had already ordered before I found you!), heath x-over pipe, new CDR valve, I modified the sending unit with the metrum rod - that was cool - and re-installed the sending unit. Also replaced all but one battery cable & the starter cable and replaced the broken trans dipstick tube. While the tank was out, did some rust cleanup & painting on the frame crossmembers where the tank goes. Also, had to figure out where to put all this new stuff on my reg cab long bed 4x4. Not much room under the cab with the xfer case, torsion bars, xmembers, etc. Felt my only options were pass side frame rail near exhaust or outside of DS frame rail under cab. Decided, reluctantly, to go on outside DS frame rail - not my favorite because you can see it and the thought of someone f'ing with it is a concern. Also had to clear the p-brake cable and brackets, so fabbed up some boxes out of 1/8" x 1" angle to mount/protect all this stuff. Drilled the sides of the angle in case I decide to install covers later. Anyway, got all my AN fittings, braided PFTE hose and everything on hand and tackled that job this weekend. Also removed the IP fitting and drilled out the holes to 5/32" and then chamfered the edges. Added a Walking-J AN fitting and popped it back into the IP. Got everything mounted, plumbed, wired, and primed yesterday and she started right up. Only one little leak where I forgot to tighten a fitting all the way. New Fuel Pres gauge is showing 14-15psi at idle with only a slight drop to about 11-12psi when I give it throttle. Let it run for about 10 mins then turned it off to install the new air box. Didn't have time to do a test ride last night to see if my problems are cured - I want to do one final safety check on a fresh head to make sure everything is tight and all wires & lines are secured. Have to say though, that Walbro pump is LOUD!! I'll try to post up some pictures of my setup later on.
So this may be a little premature since I don't know if my problem is fixed, but I just want to say thanks to everyone here for the vast amount of knowledge, helpful tips, informative posts, and excellent how-to's and lessons learned from previous fixes and upgrades. Between here & the place I feel like I can tackle almost anything on this truck. Also want to thank Leroy for his assistance and great parts at great prices. Also, 4thesporty for the inspiration and guidance on the fuel line upgrade.
