0. Describe in detail the problem you are having. Please be as descriptive as possible.

Starts great, runs great, will suddenly stall Usually restarts. May run trouble free for 10 miles, then dies like turned the key off.

1. Does the engine crank, or 'turn over'? yes
1a. Does the engine start and run? yes
1a1. If the engine does not start - Crack injector line (http://www.dieselplace.com/forum/showthread.php?p=2188140#post2188140): do you have fuel? Yes/No yes
1b. Do you have a Wait To Start Light & the amount of time (seconds) lit. yes, like 3 sec
1c. Ambient Condition (temperature outside indicate F or C) _____ ° 80 to 60 f
1d. Engine Cranking speed (if you have an accurate tachometer). n/a
1e. Are you experiencing stalling? yes
1f. If Stalling, describe (upon startup only, down the road, hit a bump etc) random, in driveway, at road speed
1g. If Stalling, do you notice loss of dash or instruments? no
-note if experiencing stalling,you must indicate PMD location in #24.
1h. Check turbo inlet and air filter for obstructions. Cone filters have lost disk and stopped air to turbo.
1.1 Lift pump test (http://dieselplace.com/forum/showthread.php?t=39350)- describe results 7 psi pre start, then 5psi while idleing

2. Service Engine Light while running?- on/off/intermittent no
2a. Service Engine light does glow during start/cranking/bulb check: Yes/No yes
3. Model year 95
3a. Odometer reading (indicate if in miles or km) 108000 miles
3b. Miles on major engine components if been replaced (example Injection pump) unknown
3c. Indicate the model number on the Injection pump (starts DS4 or DB2......)
4. Have you scanned for engine codes? (varies by pre/post 96) yes/no yes
5. List exact results on engine codes (http://www.dieselplace.com/forum/dtc.php): none
6. Air Filter condition (visual check) checked
7. Fuel filter condition (freshly changed/condition unknown/mileage since changed) bled, clear, clean, number 2
8. Condition of Battery terminal connections (removed, cleaned and tightened) new bats, cleaned all bat connections
8a. Known condition and age of the batteries. 2 weeks
8b. Are batteries of differing age or are they a matched set? set
8c. Condition of Major Grounds (http://www.dieselplace.com/forum/showthread.php?t=157085). (same drill as batt - removed, cleaned, retightened) retighened
9. Upon cold start, does the radiator hose get hard quickly? Yes/no no
10. Upon cold start, do you have excessive white smoke? Yes/no no
11. Do you have excessive cranking time before the engine starts? no
12. Have you used the block heater, and does this effect engine starting?(only try for starting problems) no
13. During hard acceleration, do you have excessive black smoke? Yes/no no
14. Do you have any unusual exhaust smoke issues? no
15. Turbo check out (http://dieselplace.com/forum/showthread.php?t=39368)- pass/fail pass
16. Do you have an EGR on the engine? (An F or an S engine code 8th VIN digit) no
17. Indicate if you know if it’s a 1500, 2500, 2500HD, 3500, 3500HD. 2500
18. Indicate fuel that you are using: Bio-diesel, #2 Diesel, #1Diesel, SVO/WVO, other #2
18a. If running a VO (Veggie Oil fuel) setup, indicate details of your conversion (homemade, or packaged system)
19. Are you using any fuel additives? If so, please list. no
20. Please indicate geographic region you are in: (example: Texas or Canada) texas
21. Do you have any service history available that might pertain to the problem you are having? 3rd pmd in less than 1 year
22. Please indicate any modifications to the vehicle that might help us diagnose better. homemade tm, relocated pmd via kit
23. Upon unscrewing the fuel cap (http://dieselplace.com/forum/showthread.php?t=42338), do you have a large vacuum formed in the tank? yes/no small amount
24. Location of PMD/FSD (http://www.dieselplace.com/forum/showthread.php?t=39436)? On the pump/remoted over intake/remoted out of engine bay (please specify placement specifically) under front bumber
24a. If remote mounted, describe wiring harness (homemade or purchased from a vendor?) vender
24b. Indicate the location and condition of the FSD/IP grounding wire. checked, on pump as stock
25. Are ALL glow plugs in proper working order as per this thread (http://www.dieselplace.com/forum/showthread.php?t=39182)? Glows seem to work find. Not a glow plug issue

I know you just got a new PMD.

If you can, let's get it out of the bumper and try to hook it up directly to the original connector, still on heatsink. Start it and see if it is stall again. This will try to eliminate the extension cable issue.

Where did you buy the PMD from?

It's the DTECH model. Plugged PMD direct to connector. Same stalling.

Try fuel filter!

Fuel filter changed 6000 miles ago. Checked yesterday. It's ok.

Okay, your Diagnostic Checklist says that this is the third PMD. What exactly does that mean? Have you put three new PMD's on in less than a year? I think we need to concentrate on this for now.

What kind of cooler are you using? Did you use heat transfer paste or a heat transfer gasket (pad) when mounting the PMD on the cooler? Did you seal the edge of the PMD to the cooler with silicone? More details please on this PMD saga...

Regards,

Did not use gasket (Silcone or lead like), used arctic silver. Did not seal with silicone. PMD was on pump when purchased. Bought Dtech relocation kit. That PMD went out, got second PMD 2 days ago. Put new pmd on. Cooler is a large 10 x 10 in aluminum heat sink finned on one side. Was part of an amplifier.

Just got it started and blew the cobs out of it. . . Ran like a demon, not a miss. . . then just about home started to miss, then while idling in the drive. . . just quit.

Have you checked the OPS? If the OPS is out you are pulling the fuel to the IP with the IP and starving it. Check the fuel flow at the WIF drain with the truck running.

7 psi before starting, and 4 - 5psi at idle. Fuel is flowing, lift pump is good.

7 psi before starting, and 4 - 5psi at idle. Fuel is flowing, lift pump is good.

I would start checking wires in the pump area. Look for any flaws in them and that the connector pins are all connecting properly. Look for lumps in the plastic coating that might be broken wires and bare spots. Also test the resistor.

checked, with snokel off

Since your in Texas (southern climate) there is a chance that you have snot in your socks (do a search if you are not familiar). IIRC, the trucks with snot will display these symptoms.

Perhaps a check of fuel pressure while driving (and preferably missing out) would be in order. That could also confirm snot since you seem to have good fuel pressure otherwise...

Regards,