Okay so to begin with the truck is a 1996 FLD classic with a Cat 3406EK motor. I bought the truck about three weeks ago and on my first run I was having a pretty serious fuel problem. It was sputtering and losing all power then surge back to life and do that until it died. I pulled the filter on the outer fuel rail and it was full of trash. I changed it and all was good for a while, then it did it again about 500 miles later and I threw on another filter and was good to go for about 1500 miles. Last night it did it again in Florida and I stopped on the turnpike and changed the filter and it took off but almost immediately lost all power and would idle fine but wouldnt let me shift through the low gears. I pulled over and waited 5 minutes and took off very slowly and it started it again but as soon as I got in the high side of the gears it quit and ran fine. I was under half a tank of fuel so I babied it to a fuel point and filled it all the way with fuel and it ran then with no hesitation or loss of power. I made it 360 miles, hit traffic and came to a stop, when I went to take off again, same thing it would start accelerating and then all power was gone, even with pedal to the floor, then after about 4 seconds it would surge like its getting fuel again and then quickly lose all power again. I got it up to speed slowly and then it ran fine in the top gears. I stopped and filled fully back up and it ran fine for another 350 miles. I stopped and filled up yet again but this time only 8 miles after completely filling with fuel it is doing this all over again. Both the fuel filters were replaced this morning and were both filled with fuel prior to installing them. I am at a loss and any help would be appreciated.
Fuel System Head Scratcher
Discussion in 'Heavy Duty Diesel Truck Mechanics Forum' started by 251guru, Nov 3, 2017.
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Maybe blow out fuel lines from filter back. Seen a similiar problen and the top foil seal of a gallon jug was stuck in fuel line and occasionly plugged line. Took a few minutes of blowing air in line to come out. If you have a rubber line failing internally it can do same thing, but of course requires a new line
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Had no o-ring on fuel filter, caused the sputtering.
You could put a short clear piece of hose in fuel line to check for air in fuel.
Good luck with the repair. -
I made sure that the o-rings were in place when I replaced the filters. I was thinking maybe it was a pickup tube issue except that the pickup tube goes in the at the back side of the tank in the middle of the tank and both tanks are slap full of fuel. So even if the pickup tube fell off the opening is submerged and could still pull fuel. I looked at the lines and I dont see where anything is cut or leaking, so I'm thinking somehow the lines have air trapped in them or the pump is failing.
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Do what cliner said. Blow the lines backwards, may be foreign material in lines.
My thought on fuel pump failing the problem would be constant.. unless it was an electrical short or loose connection.
Also as mentioned look inside the filter housing. Might have debris in there.
Good luck, let us know what you find. -
This almost sounds electrical. It makes no sense to me that it'll only sputter in low range and not in high range. Doesn't sound like a fuel problem, but I'm not a Cat guy.
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Check to see if you have the in-tank fuel heater....I think it was called "Quick Heat". Anyway there was a bulletin out there that detailed issues it could cause and basically the "fix" was to use 2 rubber balls that came in a kit to plug off one of the fuel passages. I've done it and it requires some patience using a screwdriver to manipulate the balls into the correct orifice in the fuel tank header assembly. I remember just enough to be dangerous but this is the first thing I would check as it caused a lot of problems.
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There was another heater called Arctic Fox.
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Yes but this was a Freightliner deal and used return fuel, not coolant if I remember right. Like I said earlier, I remember enough to be dangerous on this deal but it can and will cause issues as the OP is describing.
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I think he might have some algae growing in the tanks. That would explain the filters clogging so fast.
If so, a shock treatment is necessary and asap. The biocide "KILLEM" has a good reputation
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