Join Date: May 2006
Location: Montgomery, AL
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Take a pair of vice grips and pinch off the fuel return hose. It's the small one going from the engine back to the tank. You can often reach it from under the truck where it goes down along the firewall. Pinch that one off and try to start it. If the truck suddenly starts and runs fine, replace the defective overflow valve. I recommend the tork tech adjustable one for about $50. If it does not start, you haven't lost anything.
Edit: If it's not the overflow valve, then it's probably retarded timing like these guys say. If so, you don't necessarily have to buy or even borrow the full timing tool set. Jeff Garmon pointed out to a bunch of us a couple weeks ago that on many trucks, the width of the FLAT part of the crank position sensor is 7 degrees of timing if you rotate the engine with the gear busted loose from the pump. In other words, if you pop the gear off the injection pump, make a mark on the right side of the flat part I just mentioned, then rotate the engine backward (counterclockwise if you're standing in front of the truck) till the mark is lined up with the left side of the flat part of the sensor, then reinstall the pump gear, you will have just advanced the timing 7 degrees. This holds true if your damper is the same diameter as the one in Jeff's example. If not, it'll be a little more or less than 7 degrees. What I would do if I were you is this:
Try the overflow valve test. If pinching that hose does not let it start, then beg/borrow/steal the tool to pop the gear off the pump shaft, and pop it off. (You do not have to pull the timing cover, you can do it by removing the oil fill tube. Just don't drop the nut or washer when you do!) Turn the engine back 1/2 or 3/4 the width of the flat part on the sensor, and reinstall the gear after religiously cleaning the pump shaft and inside of the gear with brake cleaner so that both are operating room clean. Torque the hell out of the nut, and try starting it again.
Hopefully it's the overflow valve, but with you having taken everything apart, I'm leaning toward timing.
'98 12v 2wd dually, SB DD, Detroit locker, 64/65/13 htb2, CPP 7x10's, 3kgsk, bhaf, 19*, 50 lbs boost
Last edited by v8440; 10-27-2011 at 10:15 AM.