Hey guys, I have a 1996 Sub w/ 6.5TD. I've had some major problems with it recently: On start (winter) it would start fine, idle for about 3 mins, then die. I'd restart, it would work another 5 mins, then die again. After about 10 mins idling to warm up I take it on the road and it drives fine. This was LAST winter.


During the summer I decided that I didn't want a repeat of last year so I took it to my GM dealer's shop where they changed the fuel pump (warranty applied then) and the fuel filter. Truck still stalled on starting. Had major starting problems again and took it to the same shop again. They changed the ECM and the temperature sensor.


Guess what: Problem got WAY worse! http://www.dieselplace.com/forum/smileys/Angry.gif In addition to stalling on starting it would now start stalling on me on the highways going at 50+mph, 60+mph, 70+mph. Sometimes it would kick back up when I press the pedal but mostly it doesn't. Almost got rear ended several times!


The main problem with it not restarting again is that the glow plugs would NOT light up (the wait to start light) and the lift pump doesn't pump fuel when that happens. Sometimes I have to flick the ignition back and forth 50+ times until the glow plug light goes on for a split second and then the pump would work too and I could start it if lucky.


Help me out folks, what can I do and what could be the problem? I'm tired of dropping $600 at the dealer each time they want to "experiment" with my truck by changing things that are not causing the problem only to make it worse and cause me to risk my family's life each time we go someplace.


All suggestions welcome and appreciated!

Thanks everyone, great help you've all been!

The stalling problem I had on my 95 3500 was injector pump / little black box on the side of the inj. pump (don't remember what it was called) MIL would illuminate driving and code was for default injector pulse width IIRC. Might try there, hope that's not it as they are expensive, it's the reason I sold the truck.

Sounds like a classic FSD (Fuel Solenoid Driver) problem (the black box that a64pilot refered to). FSD failures are also heat related. However your new pump should have come with a new FSD (??). Also, when the FSD's fail they don't always set codes. How many miles on your 6.5? The other possibilties are pump wiring harness, lift pump, fuel leak or another bad injection pump.