I have an '04 Dodge Cummins 555 that dies during cool-down after towing. I recently had a BD booster lift-pump installed, and the problem began immediately afterwards. Has anyone else had this problem, and if so, what's the fix?

Unless you're racing with over 500hp, the oem '05 in-tank upgrade would serve you much better, as it's anti-foam, flowthru when fail, and the CP3 is designed for draw-from-tank service - was that BD addition installed for a failure, or just (false) security?

Installed for secuity, Why false? What does the in-tank upgrade cost?

Not sure about the DCX price for the upgrade kit, but the pump module is ~160bucks online, the upgrade harness is ~40bucks - you remove the filter-mounted pump, install the kit, which pressurizes the system from the tank, no foaming, no starving.

It is the oem-installed module on the '05-07 trucks, so it can handle the demands.

Diesel fuel foams easily - some of the add-on pumps cause excess foaming at low fuel flowrates, as at idle, so the injection pump starves for fuel after a loaded run.

If the oem filter-mounted pump is ok, some leave it in-place for added pressure and security, installing a bypass regulator to set system pressure, but the kit instructions indicate to remove it - the in-tank lift pump will push fuel thru the oem pump if it dies - it's not as easy to pull fuel thru it as to push thru it.

Considering the cause and effect, the aftermarket systems may give a sense of false-security.

So the BD pump is causing the fuel to foam? Makes sense. How involved is the install of the DCX? You get it through Dodge?
I see you have a 6.5; Who's this SS outfit that I keep hearing about?

Thanks,
Nick

I think SS is one of the vendors, here - mostly GM and 6.5 stuff

Check with Dodge for the pricing\part numbers, then go to Moparpartsdirectdotcom - the pump module is ~450bucks from DCX, ~160bucks from DCXonline

I was gonna respond to your post on the DTR forum, but had already answered it here - I think the upgrade is a '03-'04 DCX recall, covered under warranty - some there have indicated so - might check that out

Would installing an auxiliary fuel filter down-stream from the BD pump help with the foaming any? I was planning on getting the Glacier Diesel set-up since I've heard bad things about the FASS.

Thanks,
Nick

Foaming is caused by dead-heading the pump, where it builds pressure trying to move it's rated volume when the required volume is low, such as cruise, or idle - 'nuther words, it's trying to pump 50gph, and the engine demand is only 2gph - the pump thrashes the fuel, whipping it into foam.
That's a general scenario, not knowing your system details.

A filter could be a reservoir\accumulator, but would not stop the foaming

A functional system, such as the in-tank pump, has a regulator that bypasses excess fuel back to the tank, maintaining system flowrate as demand varies.

GlacierDiesel offers an adjustable bypass regulator to use with their systems - just install it between the added pump and the oem system, run the bypass output back to the tank, or tap into the oem fuel return line

I just surfed over there for a look-see - that's basically a duplicate of your lift pump, with no bypass - having no pressure guage, you could, as a test, remove the oem pump, replace it with the bd, see how it works after a run with a load.

Drawthru is a subjective term - one pump may be labeled drawthru at 26"HG vacuum - a second pump labeled draw-thru at 1"HG - your truck will die with the first one, but you won't even know the second one failed

Is that bypass regulator you mentioned the "Adjustable Hobbes Switch" Glacier has on their site?

Thanks,
Nick

The Hobbes switch is a pressure-controlled switch, good for turning things on and off at some setpoint.

The regulator is the short metal cylinder, basically a spring-loaded one-way-valve - the spring sets the pressure - install a "T" in the pressurized supply line such that the regulator can control bypass volume according to system flowrate - more fuel bypasses at idle, less fuel bypasses at full throttle - and it maintains system pressure at the regulator setpoint - thus, the lift pump is not dead-heading and foaming is reduced.

Hmmm - they show it only with the Walbro lift pump systems - maybe you can call and see if it's avalable separately

Could also check this out -

http://www.swagelok.com/search/product_detail.aspx?part=B-4CPA2-3

Seems very workable

I checked with the place I bought the truck and they told me there was no recall for my lift-pump. I understand about the fuel foaming at low delivery rates, if the stocker fails, will the BD push fuel through it? If the BD fails, will the stocker pull fuel through it? A friend of mine with the same truck had his stocker fail (Crazy Larry Mode); he put on a BD and replaced the stocker with the BD block-off plate, and hasn't had any problems, even with his programmer turned up. Sounds like that's what I should have done.

Thanks,
Nick

They're the same pump, aren't they - look the same to me, anyway, 'cept one's chromed - I s'pect the chrome one is not of American descent

Take either pump off, drain it, put a tube on either side of the pump, blow thru the inlet, suck thru the outlet - if it's not too difficult, such as drinking a thick milkshake with a straw, then it's flowthru - dunno how those pumps will handle each other when dead, but Carter advised DCX that they were not draw-type pumps, that the vanes had to be submerged to function, which meant putting it back at the tank, below tank level - you see where DCX put it - that caused all the VP44 failures, some hard, some soft.

Or, disconnect one, let the other run, and vice versa, see what resultant pressure is like

Thanks again. I found a bypass regulator here: www.vulcanperformance.com

Nick