C15 Cat wont start

They had a problem with not having enough weld surface between the baffle and the tank shell, I can't remember the year, or years, but it was corrected later by the OEM, however this didn't do anything for the tanks, (and there are many), that were already manufactured. A welding shop will remove an end cap from the tank and reinstall the baffle and put more weld surface in during the process. If the welding shop hasn't done any of these, you will need to explain all of this information to them, so that they can strengthen the installation over and above what the OEM had done.

The baffle is moving around in your tank with the splash of the fuel, it will in time just beat the tank and internal parts to pieces, you need to get this repaired before you repair possible damage to the suck tube because after you repair the suck tube, (by welding the crack), the suck tube will crack easier when it is struck again by the moving baffle, because of the weld. This also will damage the fuel gauge sending unit moving parts as you have found out.

The suck tube can be removed at the top of the tank by just unscrewing the pipe fitting at the top of the tank, as far as where the suck tube is on top of the tank, each application may have a different location so it could be on the front for some and the rear or center on others. As a general rule the return line, (if it returns in to the top of the tank), does not have a fitting for a wrench, just a female pipe port, the pickup tube will usually have a fitting attached to the tube or a hex surface so that you can remove it with a pipe wrench or cresent wrench.

 

Small line going to tank is return large line is suction side.

 

Stop using starter fluid. Prime the system and if it starts you have the issue. Why does everyone resort to starter fluid?

 

Immediate gratification.

 

And very hard on an engine, especially if it's burning nothing but ether. Very easy way to break the top compression ring.

 

I agree sounds like rocks on top the pistons or serious fuel knock.

 

Use WD-40 instead of starter fluid. Works great, lubricates cylinders, and doesn't explode like either. You can run a complete large can at one time without any problems. As the old saying goes, "Try it, you'll like it".

 

huh ? I don't use starter fluid??

 

Will buy new tube if inspection reveals crack $158.00 from intl dealer. I don't know if I can find a qualified welder for the metal, the tanks are made of. hate to be down for a week, sounds like a an expensive & time consuming job. too bad the dealer would not pick up the cost, since it is the mfg defect, but my truck is a 95'.

 

Sorry, thought you were referring to me.