1996 lost power - Dodge Cummins Diesel Forum
94-98 Powertrain Discussion of components that are directly involved in the power production and all that is needed to get and keep the truck moving . Engine , Transmission Ect...NO ADVERTISING

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post #1 of 34 (permalink) Old 06-11-2019, 05:49 PM Thread Starter
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1996 lost power

I have a 1996 3500 dump truck that all of a sudden lost engine power truck is bone stock with a 5speed 120000 miles on it. Truck is not mine. Fuel filter was change out. The truck lost engine power cant even pull a hill only in 2nd gear. The Watergate rust open took that off wired it close it help a little bit. The truck was to a shop they said it need an injector pump but I am not sold on that. I am thinking theres something wrong with AFC housing or fuel issue. Would the fuel shut off do this?


2012 cc dually 6speed, mini max, cooler delete, h&s intake horn, boost tube,5ich pipe,gdp big line kit Amsoil dealer since 2006
1996 12v 430000 miles. Built trans. 62mm hx 35 90hp injectors
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post #2 of 34 (permalink) Old 06-11-2019, 06:23 PM
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Absolutely.
I had a weird issue with my purple truck where the fuel solenoid was working fine but the little keyway on the shaft had fallen out so sometimes the truck would struggle to start, then fail to shut down because the little cam piece was slipping on the valve pump shaft.

One time right before I figured this out I was towing a customers little runabout and the truck felt like it was struggling everywhere I went. had my foot to the floor and it was just gutless. I thought the solenoid was failing so I pulled over, unplugged the solenoid and zip tied it up. Still gutless and ran terrible, managed to make it home, couldn't pull the boat up the driveway, truck just had nothing there, imagine my surprise when I cut the zip ties and the truck stayed idling as the solenoid snapped down to the shutdown position.


I'd strongly suggest looking over everything long before replacing the IP

Red Truck: 97 2500 4x4 ECLB 250k-ish, mostly stock.
Purple Truck: 01 1500 4x4 ECSB 12v Conversion, has all the 1996 3/4 ton stuff besides the body at this point.
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post #3 of 34 (permalink) Old 06-11-2019, 06:41 PM
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Check to be sure the FSS is opening all the way up? When you bled the filter after replacing it did the LP push the fuel out like it was supposed to?

Did you check the turbo shaft? How about the air filter?

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post #4 of 34 (permalink) Old 06-11-2019, 06:58 PM
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Mine blew the boost reference line off the back of the AFC once and that made the truck just gutless until I figured it out (on the side of the road). Check the little plastic line going to the back of the AFC and make sure its hooked up to a good boost reference.

97 Extended cab 4x4, NV4500, valair single disc clutch, 4k gov springs, +60 lb valve springs, homemade #10 plate, medium tension AFC spring, flat washers AFC diaphragm, stock turbo and injectors, lifted on 37" tires with re-stacked limited slip friction plates, and factory 4:10 gears.

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post #5 of 34 (permalink) Old 06-11-2019, 07:38 PM Thread Starter
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Ok guy thanks for the help if you guys think of anything else let me know. The guy wanted 4000 bucks to replace the injection pump. The guy that look at it before said it had 30psi fuel pressure. Turbo spins free and check air filter. I know it's going to be something dum wrong with it. Truck is pretty rusty under the hood.

2012 cc dually 6speed, mini max, cooler delete, h&s intake horn, boost tube,5ich pipe,gdp big line kit Amsoil dealer since 2006
1996 12v 430000 miles. Built trans. 62mm hx 35 90hp injectors
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post #6 of 34 (permalink) Old 06-11-2019, 07:46 PM
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Quote:
Originally Posted by pa coal roller View Post
Would the fuel shut off do this?
This happened to me a week ago. A little hard to start, needed pedal to get going, very low power but would free rev to 2600 easily. I carry a spare, this has happened to me before. Fixed in 30 minutes.
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97 3500, 2 WD, G56, slightly bombed, 1.3 million miles. Started the second million on 8/24/13
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post #7 of 34 (permalink) Old 06-11-2019, 07:46 PM
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I've seen the FSS rusty on the pump end and wouldn't let it open all the way.

84 K5 Blazer 97 12v, 47re with E-TransControl, Dodge Dana 60 with free spin hubs, Dana 70, B&M Mega shifter

96 F350 SC dually zf5, 4x4, 92 Cummins, THD 5x12's, THD fuel pin, THD HVLP with adjustable fuel pressure mod, WM, h1c 60/60/12cm WG wired
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post #8 of 34 (permalink) Old 06-11-2019, 09:00 PM Thread Starter
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I wont get to look at it till the weekend. . That will be the first thing I check will be the shut off.

2012 cc dually 6speed, mini max, cooler delete, h&s intake horn, boost tube,5ich pipe,gdp big line kit Amsoil dealer since 2006
1996 12v 430000 miles. Built trans. 62mm hx 35 90hp injectors
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post #9 of 34 (permalink) Old 06-11-2019, 09:21 PM
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Quote:
Originally Posted by GAmes View Post
This happened to me a week ago. A little hard to start, needed pedal to get going, very low power but would free rev to 2600 easily. I carry a spare, this has happened to me before. Fixed in 30 minutes.
I'm waiting till you write your memoirs (a book)...I'll be at the front of the line to buy and get a signed autograph....
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post #10 of 34 (permalink) Old 06-11-2019, 09:32 PM
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I'm waiting till you write your memoirs (a book)...I'll be at the front of the line to buy and get a signed autograph....
LOL. One only need to read this forum and the TDR to get my truck history. I'm too lazy to collate it. The FSS broke the morning after we had met for beer.

97 3500, 2 WD, G56, slightly bombed, 1.3 million miles. Started the second million on 8/24/13
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post #11 of 34 (permalink) Old 06-12-2019, 08:07 AM
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Quote:
Originally Posted by GAmes View Post
This happened to me a week ago. A little hard to start, needed pedal to get going, very low power but would free rev to 2600 easily. I carry a spare, this has happened to me before. Fixed in 30 minutes.
If you've experienced multiple broken solenoids, why not go the pull cable route and eliminate it all together? Wouldn't be any need to carry a spare then.

97 Extended cab 4x4, NV4500, valair single disc clutch, 4k gov springs, +60 lb valve springs, homemade #10 plate, medium tension AFC spring, flat washers AFC diaphragm, stock turbo and injectors, lifted on 37" tires with re-stacked limited slip friction plates, and factory 4:10 gears.

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post #12 of 34 (permalink) Old 06-12-2019, 08:31 AM
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If you've experienced multiple broken solenoids, why not go the pull cable route and eliminate it all together? Wouldn't be any need to carry a spare then.
Two in 22 years and almost 1.4 million miles does not constitute "multiple". In case you aren't aware, cables break and fittings come apart. Besides, I don't want to hack up my dash, drill a hole in the firewall, find a route for the cable and end up with a disfigured interior.
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97 3500, 2 WD, G56, slightly bombed, 1.3 million miles. Started the second million on 8/24/13
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