I finally got to the first stage of my truck. I finished installing my Fleece Sureflo sending unit. I've run into a couple of issues. First, the tabs holding the rear plastic inner fender did not fare well during their removal. I don't know the correct names for these or where to find them. Does anyone have any ideas, or better yet, point me in the right direction? Second, after lowering my spare tire, I noticed the cable winch thingy is breaking apart. Plastic was falling out everywhere as I was lowering it. Has anyone else dealt with replacements?

45 minutes ago, 1361 said:

point me in the right direction

Google push pin rivet.

 

47 minutes ago, 1361 said:

Has anyone else dealt with replacements?

I picked up a spare in the pick apart yard.

NAPA has a full assortment of plastic fasteners typically just take an old fastener with you and match them up. Like I did big bags of the door panel fasteners from Amazon. 

Push pin rivets? I would have never figured that one out. Turns out the big river had both the rivets and spare tire hoist. Thanks for the quick responses.

Round two...

 

I installed the sending unit for the fuel pressure gauge. I decided on just keeping the fuel filter canister included in the run. I didn't want to mount it onto the VP. I think I'm going to need an elbow for it. It's sure is close to the motor mount. I don't think I'll get the plug on the end. Either that, or eliminate the banjo bolts and go with an inline setup setup. The elbow would be the easiest option.

 

Onto my next issue . While fiddling with the sending unit, I notice I broke what I believe is a vacuum line. I have no idea what it's for. It seems much more flexible and spongy than a normal vacuum line. Perhaps because of age. Normally, lines like this get hard and brittle, not soft and spongy. Also, the small line next to it does seem like it's in much better shape.

 

What kind of lines are these?

The lines you are referring to are vacuum lines for the operation of HVAC system ventilation doors, 4WD selection, and in your case cruise control (automatic transmission).

 

The large 90° fitting in the middle close-up photo is the connection to the source of vacuum - the vacuum pump.  You probably have many deteriorated lines / fittings that will need to be addressed due to the age of your truck.

 

- John

https://puredieselpower.com/dodge-products/2nd-gen-12v-94-98/upgraded-and-replacement-parts-3/97-02-dodge-cummins-vacuum-feed-line-hose-55056421aa-55056421aa

Thanks again for all the help. I ordered one this morning.

I found this thread on CF with a diagram and part numbers.

55056421AA - Engine
52105317AB - Transfer Case
52105299AB - Front Differential

I'll probably get the two other line assemblies as well. Like you said, after 22 years they're all ready to be replaced. That said, one thing at a time for now.

Buttoning everything up went well. I decided to put on the stealth plate on the pump. I was quickly reminded that it's always something. The first bolt I tried to take out stripped out on me with very little pressure. Son of a *****. Any ideas on getting this out? I've never had much luck with easy outs. Once I get it out, I'll need to replace it. Where would I even find such a bolt. I can't imagine ace would have such things. 

 

Put everything back together and went for a quick test drive. I had the fast blinker indicator reminding me I forgot to plug in my tail light from doing the sending unit. I backed my truck half way into the garage and tried to shut it down. No go. The truck wouldn't shut off. No doubt from me dinking with the settings in the iquad app. I sorted that out, plugged the tail light back in and parked my truck.

 

There was a nice big spot on my driveway from the truck idling. A fuel leak near the sending unit. I suspect when I cracked the valve open for my fuel pressure reading, I may have opened it too much. Could I have blown out my sending unit? Or, maybe I just didn't get everything tightened up well enough. 

 

Today wasn't my day.

It's always something.

Hmmm... I've never had any issues on pull the PSG cover. You need to have the exact bit for the cover bolts there are not a standard torx bit its actually a special bit. I normally get a 1/4" socket and put it on a 1/4" ratchet and just place the bit in the socket and twist like a palm ratchet and they come right loose. If im not mistaken the PSG cover bolts are a 5 spline bolt and a normal torx bolt is a 6 spline. 

I had one strip on me too when I went to put on the stealth cover.  I just left it and never put on the cover yet. 

 

They sent me the 5 star bit, but it was not the right one. My bolts are six star like regular torx. I used a 1/4" drive torx socket. It fit in there tight before I started. It's buggered up now though. So, I've got to get it out and find a new one to put back in. Any ideas where I might find a new one?

Take a good one to Menard. In the bolt section,  they have thread checkers. Once you know the diameter and thread pitch, they might have one.

If not, you will know the specs and can check Napa or online. Diameter, thread pitch and length are important.  Head configuration isn't.  Hex, Allen or torx will work.

If you have a dremel with a cutoff wheel, you can make a regular screwdriver slot in the head of the PSG stripped bolt to remove it.

[quote]Take a good one to Menard. In the bolt section,  they have thread checkers. Once you know the diameter and thread pitch, they might have one.

If not, you will know the specs and can check Napa or online. Diameter, thread pitch and length are important.  Head configuration isn't.  Hex, Allen or torx will work.[quote/]

[quote]If you have a dremel with a cutoff wheel, you can make a regular screwdriver slot in the head of the PSG stripped bolt to remove it.[quote/]

I may end up doing just that. However, I prefer to have the part in hand before I take it apart.  I work in my garage. But my truck wont fit in my garage and allow me to close the door. It's just too long. It has to sit outside every night so I can close up. I'm trying to get new bolts before I tackle this again. I going to call Oregon Fuel Injection today and see if they have and can send me what I need.

 

I have a dremel and that will probably be my next step. That is, after I verify I have the correct bit/tool to remove the other bolts. The torx I used seemed right, but my eyes are failing so... But I'd like replacements in hand before I start at it again.

 

 

Oregon Injection hooked me up with some new bolts. It's just going to be a week or so because they're coming from Bosch. Bosch won't ship directly to me.  So as soon as they get to Oregon, they'll send them down to me. I ordered six just to have an extra. Because, well, if I have an extra I won't need it. If I don't, I will.

hdpwipmonkey, I'll gladly send you one of my old ones if I can get the rest out in good shape.  I'm not touching this again until I have the new bolts in hand so it may be a few weeks.

 

10 hours ago, 1361 said:

Oregon Injection hooked me up with some new bolts. It's just going to be a week or so because they're coming from Bosch. Bosch won't ship directly to me.  So as soon as they get to Oregon, they'll send them down to me. I ordered six just to have an extra. Because, well, if I have an extra I won't need it. If I don't, I will.

hdpwipmonkey, I'll gladly send you one of my old ones if I can get the rest out in good shape.  I'm not touching this again until I have the new bolts in hand so it may be a few weeks.

 

Sounds like a deal.  I'd be happy to buy 2 from you (so I have a spare, just in case).  Just let me know how much.

I put my injectors in today. Have I mentioned how much I've come to like my new topside creeper? Best investment ever. While everything was apart, I decided to get some better pictures of the cover bolts. I was starting to wonder if my age was catching up with me and I made a mistake. They are definitely reg T25 torx bolts. I was tempted to give it another try and do the cover too. I restrained myself and I'll just wait for the new bolts first. Side note, new injectors, even without the wire tapped are nice 

 

1 hour ago, 1361 said:

They are definitely reg T25 torx bolts.

 

Not trying to second guess you here as I don't know what size they are, but there is a Torx 27 tool size as well.  It would be easy to think a Torx 25 would be the correct tool.  It might be worth double checking.

 

- John

I'm almost positive it's a T25. But now that you say that it has me wondering. I'll double check when I get the replacements and take everything apart again. 

True Bosch certified pump is NOT a T25. Look security pin in the center and its not 6 point but 5 point.