First I would confirm that your JWAM is reading correctly. I have had on more than one occasion seen those read low. Especially under WOT. (Im not a huge fan of electric gauges)
ALSO how are you taping for fuel pressure? Did you keep your stock fuel filter in line? If that is the case, I would suggest using a fitting from one of the following places to put the tap in-line and take the filter head out of the equation:
Power By Poole Diesel Performance
Vulcan Performance Home Page
Mr. Gasket Barb Fuel Pressure Gauge Fitting - JEGS
If you have a know working mechanical gauge...i would suggest checking with that to get a confirmation of pressure.
ALso might try the 5 gallon bucket test. Basicly fill a bucket of fuel up and place your suction and return line into it. Then run the pump and see if your pressure improves or not. Then hook up the return line of the FASS back up to empty the bucket and fill your tank in the truck up.
Then we can try a few other things if the pressure is confirmed correct.
As for the fuel blowing out at you if the truck is still running when filling up, you have the older style return manifold that tapped into the Vent line of the tank for the fill neck. We updated this about 2.5 year ago to a manifold that splices into the actual neck and eliminates this scenario. The part number is RM-1002 for your year truck. Any FASS dealer can help you convert over to this newer style.
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Dan MacDonald
www.FASSRide.com
2001 2500, 4x4, Con OFEed, TBK, AFE Stage II kit W/ prefilter and 4" cowl mod. , FASS 150/150, Mach 2's, Drag Comp,
Currently running on B-100
'02 Jetta TDI 5 Speed "Mini Me" 45-50 MPG