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Almost ran out of fuel prematurely again

R

Rodd

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Location
Antelope, CA
I have a bone to pick w/ some of you guy's. Since July I have run out of fuel or had symptoms of it approximatly 10 times. I replaced my fuel sending unit in July. I have had my tank down approximatly 5 times since then. Each time my baffle was out of place and my new fsu was bent so the truck would starve for fuel prematurely. Each time I had my tank down I drained it into a 55 gal drum w/ a double layered sheet over it to strain out any crap in the tank. I assumed my fuel cap was failing, which caused my tank to start to impload thus bending the fsu. Well when I replaced the IP at Thanksgiving I removed the rubber gasket on the fuel cap thinking it would fix a bad fuel cap. Well w/ 400 miles on a full tank today (luckily just around the corner from my house) it started to start to slightly cut out. I dropped the tank and the baffle was out of place and the fsu was bent again. This time I got lucky. I noticed 2 washers just below the fsu whole. I looked around and saw a 3rd. No one ever said that the baffle needed washers to hold it down. I had never noticed them before in the many times that I had the tank down. I had looked for something to hold the baffle down but nothing. When i posed back in July no one said anything. Each time I had the tank down they never came out w/ the fuel and I never saw them. I thought the fuel w/ the fsu on top of the baffle made it stay in place. Since my arms are too big for the whole I used a magnet extension that I got a Harbor a few years back to fish them out and fasten the baffle properly. I also bent the baffle so it was about 1/8-1/4 inch off the bottom of the baffle. One thing I noticed w/ the magnet is it picked up all the little pieces of metal that are just floating around. I didn't have many but if you ever have your tank down I would suggest doing it just to clean the tanks.

Sorry for the rant.
 
Rodd IIRC at old site I posted pics of the retainer buttons, when I did the fuel tank replacement in the burb, my baffle also had come lose, and rust in bottom of tank is why I have the frame rail Racor in front of the lift pump. I'm sorry for troubles thus far buddy, but hopefully you got it fixed for good now,

I used "fingers" to position washer over the plastic post then long screwdriver to mash down keeper washers fully seated down, my baffle trays are plastic.
 
I just can't believe I missed the washers in the many times I had it down. I guess I was lucky this time that I saw them. I originally thought that my wifes accident jogged it loose until I saw the washers.
 
ghitch75 said:
my 95 has no baffle in it.....is your a 42 gallon between the frame in the rear?
Click to expand...

yes it is to both questions. The only thing the baffle does is when the tank is getting low and you go up a hill it fills the baffle so all the fuel doesn't run to the back.
 
Well it happened again. I haven't dropped the tank yet but it ran out of fuel w/ just over 400 miles on it. When I filled it up it it only took 32 gallons which means there were 11 left in the tank. I know the last time I found the washers and was able to put secure the baffle on with them. I don't know how it came off again. Does anyone know of an adhesive that will not degrade in diesel?
 
Give Loctite a call. I'm sure they have something that will work.

Loctite® Brand Consumer Products
M-F, 9am - 4pm EST (800) 321-0253
 
Rodd said:
Well it happened again. I haven't dropped the tank yet but it ran out of fuel w/ just over 400 miles on it. When I filled it up it it only took 32 gallons which means there were 11 left in the tank. I know the last time I found the washers and was able to put secure the baffle on with them. I don't know how it came off again. Does anyone know of an adhesive that will not degrade in diesel?
Click to expand...


Mine also runs out with approximately 11 gallons left in the tank. Think my baffle came apart? I don't understand exactly what's going on...
 
Matt Bachand said:
Mine also runs out with approximately 11 gallons left in the tank. Think my baffle came apart? I don't understand exactly what's going on...
Click to expand...

I have a 22 gallon tank as front and another one in rear, but my front one show OOF symptoms, at refill it takes about 11 gallons.

I must have disrupted something when blowing air into the tank, what could it be?
 
I have been and still going through the same/similar issue. I have the 34 gal tank and it is new as well as the sending unit. It seems the sending units that are after market do not get down as deep as the origional sending units did even if it's an a/c delco. My suggestion and what I will be doing soon is dropping the tank again and taking the sock off and bending the tube down into the tank and installing an after market filter system to compensate for what's been removed, which won't take much.
I can't go beyond 1/8 of a tank and go up a hill without stalling or sputtering with the current set-up.
Hope this helps.

Mark

P.S. TD has the answers if you pay attention. Very wise person in the 6.5's. I've learned from his as well.
 
kimagine said:
I have been and still going through the same/similar issue. I have the 34 gal tank and it is new as well as the sending unit. It seems the sending units that are after market do not get down as deep as the origional sending units did even if it's an a/c delco. My suggestion and what I will be doing soon is dropping the tank again and taking the sock off and bending the tube down into the tank and installing an after market filter system to compensate for what's been removed, which won't take much.
I can't go beyond 1/8 of a tank and go up a hill without stalling or sputtering with the current set-up.
Hope this helps.

Mark

P.S. TD has the answers if you pay attention. Very wise person in the 6.5's. I've learned from his as well.
Click to expand...

The last time I had the tank down I compared the new s/u to the old one and bent the new one down to about 1/8" off the bottom of the tank.
 
Rodd said:
The last time I had the tank down I compared the new s/u to the old one and bent the new one down to about 1/8" off the bottom of the tank.
Click to expand...

I wish I had thought about that when we did it.:mad2: What kind of sock did you have on the new SU? I had to drop the tank again to change it as the after market one was small and clogged very quickly which started to leave me stalled slowley until finally leaving me to be towed home.
We created a special sock from NAPA which was much larger and had to customised to be put on. If I have to drop the tank again, I will bend the pick-up down and install an exterior fuel filter and be done with dropping the tank.

Mark
 
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