Well new to me at least!

Some of you helped me out in my other thread when looking for one. Well I finally pulled the trigger and picked one up!

It's a 2002 4x4 QC LB auto. Single owner, garage kept majority of its life, never had a goose neck or 5th wheel (which is harder to find than you'd think up here). Came with a 2in leveling kit and 35's and a hypertech 'tuner' to fix the speedo. Other then that, she's all stock. I crawled under to check for any signs of a 53 and couldn't find anything, so I might have a mexican block, but I'm going to keep checking. I couldn't be happier! I originally wanted a manual, but the wife said, if I'm getting a new truck then she better at least be able to drive it. So rather then argue, I just said 'ok' and got lookin!

Anyways, wanted to start a thread here because, since it is stock and I'm planning on keeping this truck for the long haul, I wanted to do some mini write ups of the mods and what not I get done to her. As of now, here's the order I want to go in:

1. FUEL! and lots of it!

2. Gauges

3. Steering

4. Transmission

5. More power!

3 and 4 may get swapped around depending on what's needed more and my budget but that's the general order.

 

So to start, fuel... The stock injection pump was replaced by the dealer 50-60k miles ago so it should have some decent life left, and it looks like they moved the stock lift pump. I didn't track it down exactly, just looking fairly quickly, and couldn't find it mounted on the frame, did they do in tank LP's for 02's? I'd like to fatten up my fuel lines to 3/8s everywhere possible, also looking to go with the Fuel Boss, but not sure how that works if my LP is mounted in the back in tank if that's even a thing. Any ideas or experience with this? As of now I'm looking at getting the following for step 1.

FUEL BOSS ----- BIG LINE KIT ----- MOD FUEL MODULE

As far as fuel lines, the obvious is the big line kit from Vulcan but I figured I'd talk with Eric about getting lines replace as much stock line as possible. I also threw on the modified fuel module. I saw that as I was browsing their site and hadn't seen it before. Is that necessary at all? Keep in mind I'm just looking to have fuel flow as easily as possible through the truck. When more power rolls around I don't plan on going EXTREME, but would like lack of fuel to never be thought of again after this.

I'll leave at this for now but really looking forward to wrenching on this truck and getting her setup for the long haul!

The return hose for the AD came with the ends already on them. It was just plug and play quick disconnects. I have heard people have had problems out of them. Mine have been trouble free, though I might be have an issue with them now I just need some decent weather to investigate that. All of my lines came with the ends already on them. The VP and engine return lines just stayed stock and plugged back into the existing return on the basket. Pretty simple actually

Actually one end had quick disconnects you just pinch and release and the other end needs a removal tool to disconnect them. Not sure why they were different on each end. Must be an AD thing.

Ah ok. On my setup, the only stock lines that are still being used are going to be the stock return line from the VP. If AD didn't have the QA 'issues' as of late I probably would've just gone with them since they seem to do this process on their system. I'm basically trying to merge the AD fuel module setup with the FASS setup.

Either way I think I got the kinks worked out from my screw ups and things should work out.

I just need to try and clean my tank out as best as possible and then everything's going back on the truck.

I went a similar route as dripley and my vp returns through the OE quick disconnect and Fass returns to the OE pick-up. I just did what Eric said the disable the check valve so all the return fuel goes right back into the basket. I've only ran it down just until the fuel light turns on at 1/8 of a tank and all was well so far

On ‎2‎/‎8‎/‎2016 at 7:52 PM, IBMobile said:

He pulled me over.  Said he was looking for you.  I pled the 5th.    

I'll never park next you after the stuff I found in my truck. No wonder he's looking...

Edited February 26, 20169 yr by JAG1

37 minutes ago, BBHD said:

I went a similar route as dripley and my vp returns through the OE quick disconnect and Fass returns to the OE pick-up. I just did what Eric said the disable the check valve so all the return fuel goes right back into the basket. I've only ran it down just until the fuel light turns on at 1/8 of a tank and all was well so far

What check valve are you referring too?

2 hours ago, notlimah said:

Ah ok. On my setup, the only stock lines that are still being used are going to be the stock return line from the VP. If AD didn't have the QA 'issues' as of late I probably would've just gone with them since they seem to do this process on their system. I'm basically trying to merge the AD fuel module setup with the FASS setup.

Either way I think I got the kinks worked out from my screw ups and things should work out.

I just need to try and clean my tank out as best as possible and then everything's going back on the truck.

The only stock lines I used were the VP/engine(back of the head)lines. They are joined by a tee at the back of the engine. Your are pretty much doing the same thing(return fuel to the basket)in a different manor. Both ways work.  think you did the right thing getting a Fass and not the AD. 

Not sure i remember a check valve, but i did install mine 5 years ago. 

3 hours ago, notlimah said:

What check valve are you referring too?

just above where the in tank pump was mounted. Yours is cut out now where you have a larger return for the FASS. I just used the quick connect that came with my pump that has a quick connect to the stock suction. I hope that makes sense 

I removed all of that from mine, thats why I dont remember it.

I like the tekmats.

16 minutes ago, CSM said:

I like the tekmats.

If he had used those he would have got some serious power to the VP.

Ok @dripley & @BBHD I think I'm trackin with what you're saying. You just used the OEM suction lines, just used a quick connect and added it to them. Either way I think were all ending up with the same result, just taking different ways of getting there!

Mine is 1/2 suction via the drawstraw, 1/2 return from the FASS via extra fitting/straw, and the OEM return from VP/engine to the OEM return port up top.

So here's an update on my slow progress (its tough getting work done with a 14week old at home!)

So I got my module finalized with wires clipped that I don't need anymore, the OEM suction hose gone, and put a small yellow rubber screw cap on the end of the OEM suction line. I filled it with JB weld and slid it over and let dry, that way no debris would be able to get inside.

I'm hoping I have enough hose to run my return and supply lines to the FASS since my fitting are facing the opposite way, but I'm sort of limited with where they can go due to stock fittings. Should work out no problem, and worse comes to worse I'll order more hose.

Oh and if anyone was every wondering the size comparison between the stock carter, in tank pump and the FASS, here ya go!

Edited February 29, 20169 yr by notlimah

I was surprised when I saw the in tank pump and the fact that a portion of the flow of that pump is diverted to open the little flapper in the bottom of the basket to help draw fuel into the basket. Lot a work for that little pump to do.

You should have enough hose to route then the way you want. My DSV fitting is facing the same way. I had enough hose to run to stock filter housing then to vp and still had about 16" left. Never used the 1/2" line that came with the big line kit. Awesome thread with great pics by the way  

Edited February 29, 20169 yr by BBHD

17 minutes ago, dripley said:

I was surprised when I saw the in tank pump and the fact that a portion of the flow of that pump is diverted to open the little flapper in the bottom of the basket to help draw fuel into the basket. Lot a work for that little pump to do.

I thought the same thing. I mean, I'm not sure what alls workable on the carter and what's "for show" sort a speak, but it's pretty crazy what a difference they are.

13 minutes ago, BBHD said:

You should have enough hose to route then the way you want. My DSV fitting is facing the same way. I had enough hose to run to stock filter housing then to vp and still had about 16" left. Never used the 1/2" line that came with the big line kit. Awesome thread with great pics by the way 

Good to hear! Hoping to get the fuel module back in tank and tank back on the truck tomorrow!

Anyways, more to come!

Only problem with FAS it so friggin' huge...

Makes for difficult time hiding the pump and filter somewhere out of the debris path of the tires also out of the direct wind of winter cold. So the FASS can't go in my hiding spot. It just too big. So consider you mounting location very careful. Frame rail mounting will place the filters in striking path of any kicked up road debris. It would really suck to run over something and wipe out the filters. 

 

I have a swing away protection plate using 1/4'' aluminum plate under my large Racor filter. When I need access I loosen one bolt and the plate pivot/ swings out of the way. Basicaly it is an extension of the skid plate already under there but, lapped the correct way to not snag anything.

Edited February 29, 20169 yr by JAG1

That's pretty much what I was planning on doing as well! I want easy access for filter changes but don't want road junk flying into it.

***PROGRESS REPORT***

Well got these fuel module reinstalled in the tank. 

Of course as soon as I snugged it down I panicked and couldn't remember if I plugged in the electrical connector inside, so off it came! (Of course it was plugged in)

Used the ol harness hoist maneuver to get the tank back up under the truck

I'd highly suggest that you shave down your forward most tank strap. It makes it possible to get the strap out without loosening the carrier bearing bolts.

I probably should've trimmed more off since I still had to muscle it into place but it was still doable with all the carrier bearing bolts fully tightened down. 

Anyways, tanks still slung under the truck loosely so I can route hoses for the FASS tomorrow. Started to route the wiring but these little s@!#s broke! Both the ones supplied from FASS broke so it was off the ACE I went 

It wasn't a huge problem, and my fault but set me back enough that I killed all my remekning daylight. So tomorrow I'm hoping to get the FASS wiring and tubing done tomorrow and should make good headway on the gauge install as well. I'm not planning on teeing into the stock fuel filter and I don't need to cut the filler tube so I'm hoping that saves some time. 

Anyways, more to come!

On ‎2‎/‎29‎/‎2016 at 6:59 PM, notlimah said:

Oh and if anyone was every wondering the size comparison between the stock carter, in tank pump and the FASS, here ya go!

That little in tank pump looks just like the type Volvo used in their tanks (1976-1992) to feed the main Bosch fuel pump. They didn't hold up to well either.

Need some feedback real quick guys! Officially unpacked and got the FASS pump dressed up with all the fittings and what not, only to realize I have a dent on the bottom on the fuel filter. Is this enough to warrant a new one or am I good to go?! 

I'm already looking for local replacements if neccesary.