98.5 and 99 VP44 troubles

[bent valves]

I don’t know how many forum members own truck from these years. Here is a heads up that may keep your injection pump (Vp44) alive.

Earlier this spring my motor just quit as I was driving. Fuel pressure was good, temperatures were cool, perfect driving conditions. After towing it home and scanning for codes, I did not find the infamous P0216. Instead I retrieved P0253: Fuel injection pump fuel valve Open Circuit and P1688: Internal fuel injection pump controller failure. Hmmm, electrical failures, not mechanical.

As I changed the pump out I found the rear pump mounting bracket broken. The injection pump beat itself to death. With this bracket not supporting the VP44, it is only mounted by the front to the aluminum gear case. The circuit boards or connecting wires to the internal solenoid valves failed because of mechanical vibration. The shaft on this bad pump spins smoothly as I twist it indicating no serious mechanical problems.

Here is the heads up: Reach down under the back of the injection pump below the high pressure lines, feel for the steel bracket and round cylinder that should be welded to the bracket to see if it is loose. I wish I had done that. See photo of the bracket with the broken welds. The broken welds show a layer of rust from our New England winter indicating the bracket failed some time ago.

The good news is Cummins has redesigned this bracket twice. The latest version is Cummins part # 3938707 and has the description, “Kit, fuel connection” which seems a little odd. The bad news is the only way to replace it is to remove the power steering pump to get access to the 2, T40, torx screws holding the bracket to the engine block.

The Y2K model year started using the first revision bracket which looks pretty beefy but not as strong as the second revision. The second revision is a heavy plate that bolts to the bottom of the VP44 and a cast steel piece that mounts to the engine block using the same two torx screws. (Sorry no pictures.)

If you go this route, Cummins made another change. The power steering pump also connects to this bracket, both old and new. I had to relocate the “L” shaped tab that was on the top of the power steering pump to the bottom of the pump. No instructions were included with the “Kit, fuel connection” to show this change.

It may be a good idea to get the latest bracket if you are about to replace one of those wonderful VP44s The cost from Cummins is about $50 and include most of the screws needed. You will have to salvage some screws from the old bracket.

Attached Images

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Dave
1998 24Valve, BD dual turbo, Mach 4, Smarty, APB, ARP studs, Rickson 19.5s, DPP 4" SS, CON OFE.

[mrmajestic]

Thanks for the info!

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1999 2500 Quad Cab, 5spd, 4X4, 3.55 LSD, 152K miles, Buckstop w/9K winch, Torque King M/S, K&N FI Perf Kit, 275HP Inj., TST PM3/Smarty stack, PDR boots, Wabro/Areomotive and 1/2" line, PAC Brake w/SWAC, Summit Turbo back 4" pipe, EZ drain, silencer ring MIA, pyro/boost/FP gauges, SBC Con OFE w/HD Adj Hyd, Brite Box, DSS, Centramatics, BFG LT285/75R16/E

[mgstroker95]

Hey bent is there anywhere you can purchase this online or do you have to go to a cummins dealer! Thanks

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2007 Dodge 2500 4x4 5.9 Cummins, Black Pearl paint, Rhino Bedliner, Auto Meter Oil, Boost, Water temp and Fuel pressure Gauges, Ranchand Legend front replacment wtih a Tuff Country rear replacment, N-FAb nerf bars, AFE Stage 2, Smarty programmer, Amsoil fluids, WeatherGuard box, 18% tint all the way around, Geno's muff delete, MBRP 5" tip

" I can do all things through Christ who strengthens me " Phil.4:13

[bent valves]

I found the VP mount at the Cummins dealer after getting a price for the second version at the dealer. I don’t know if the Dodge dealers will be upgrading to the latest version or not.

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Dave
1998 24Valve, BD dual turbo, Mach 4, Smarty, APB, ARP studs, Rickson 19.5s, DPP 4" SS, CON OFE.

[mgstroker95]

Thanks Bent

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2007 Dodge 2500 4x4 5.9 Cummins, Black Pearl paint, Rhino Bedliner, Auto Meter Oil, Boost, Water temp and Fuel pressure Gauges, Ranchand Legend front replacment wtih a Tuff Country rear replacment, N-FAb nerf bars, AFE Stage 2, Smarty programmer, Amsoil fluids, WeatherGuard box, 18% tint all the way around, Geno's muff delete, MBRP 5" tip

" I can do all things through Christ who strengthens me " Phil.4:13

[DIESELMAN3500]

yeah i feel ya, i found my bracket broken as well while replacing my vp44.
nice catch!
hey i re-welded mine do you think this was a bad decission? should i get the newer bracket in fear that this will happen again?
thanks!

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98.5 3500-22.5" Rims, 2" lvl kit, LED,EdgeJuice/Att,4dwnpipe,ATS 3 Pice Manifold, ATS PerformanceTRans,ATS T/C,custom fenders,ATS CoPilot,6" Bull Horns,Guages FASS Fuel Pump 95Gal,Hadley Air Horns, BHAF, Guages, jammer3, Lnd Visor,Dipricol Gauges

[bent valves]

Sorry to take so long to get back to you.

I was going to re-weld my bracket but after looking at how the weld broke, I decided not to chance it. The factory-welded bracket showed good penetration and actually cracked and broke through the weld material itself. There must be a lot of vibration and stress at that joint and over time it fatigued. If you were to add a metal filler piece between the bracket and cylinder it might hold up much longer.

Cummins changed the design twice because of problems with the breakage. If they could have made an easy fix to the first design they would have done that instead of investing the engineering design time on two more brackets. I believe the latest bracket at $50 is the best answer only because if a repaired bracket breaks again, it is such a pain to replace it. Those VP44s are not inexpensive either.

Best of luck in whatever choice you make.

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Dave
1998 24Valve, BD dual turbo, Mach 4, Smarty, APB, ARP studs, Rickson 19.5s, DPP 4" SS, CON OFE.

[99 cummins]

For what it's worth, here is a link to some additional fueling problems in these systems.

Fuel System Troubleshooting Guide

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99 Quad Cab, 4wd, Comp Box W/Pump Wire & Boost Elbow installed, K&N Air Canon, MBRP exhaust, Twin PE 4200 High Pressure Fuel Pumps W/Fleetguard inline filter, Isspro EV Pyrometer, Boost Guage, Fuel Pressure Guage, DT Pro Fab Trac Bar, South Bend 13-1.25 Con O Clutch, Royal Purple Synthetics all around

374.2/846.7 at 30psi

[bentwings]

Part of the problem when replacing the IP and this bracket is that it often is bolted tight to the pump then the pump is installed on the front cover. When you tighten the other bolts against the block there can be a bending load placed on the bracket, pump and front cover because of the excess clearance inthe bolt holes.

When instaling the new pump, bolt the bracket to the pump but just barely finger tight. Install the pump on the front cover tightly. Then from down under you can evenly tighten the 4 bolts on the bracket. This will insure and even distribution of support. It's a little more work but a better done job.

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'99 Quad cab 3500 SLT, dually, black, rwd, 5 spd, 4.10, brushguards, towing mirrors. fuel pressure gage, muffler lost, lift pump victim. now VP-44 victim , 19/20 mpg . Smarty
and yes... the plane will fly. older than dirt

[DIESELMAN3500]

yup my bracket broke again great huh...:fist:

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98.5 3500-22.5" Rims, 2" lvl kit, LED,EdgeJuice/Att,4dwnpipe,ATS 3 Pice Manifold, ATS PerformanceTRans,ATS T/C,custom fenders,ATS CoPilot,6" Bull Horns,Guages FASS Fuel Pump 95Gal,Hadley Air Horns, BHAF, Guages, jammer3, Lnd Visor,Dipricol Gauges

[DIESELMAN3500]

ok quick question, got the newest beacket, do i use the same bolts to the block as before hand? because they are a smaller diamater than the hole on the black cast that is in the box, is this going to vibrate loose? and to get a bolt that fills the hole drilled in the black cast is going to reguire me to drill and tap the engine block which im not all for doing. any help to installing this piece of hardware would greatly be appreciate.
thanks!

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98.5 3500-22.5" Rims, 2" lvl kit, LED,EdgeJuice/Att,4dwnpipe,ATS 3 Pice Manifold, ATS PerformanceTRans,ATS T/C,custom fenders,ATS CoPilot,6" Bull Horns,Guages FASS Fuel Pump 95Gal,Hadley Air Horns, BHAF, Guages, jammer3, Lnd Visor,Dipricol Gauges