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Second Cummins.. still have questions

12K views 121 replies 8 participants last post by  crazzywolfie 
#1 ·
This thread is all about my second Cummins, I'm a question machine so here they are for this truck.

It's a 1992 D250 automatic.

First, a bunch of pictures followed by what I know about it so far.
 
#13 ·
Typical cab floor and rocker rust. They make replacements for those. Borgeson shaft - good. FASS - suggests it's been dialed up a bit. That IP recently rebuilt? you'll need to clean it to see if the grease/oil is engine leaks or road grime
 
#14 ·
So the good things:

It has a 4" exhaust, but not from the tubro, its welded to the down pipe
Borgeson steering shaft
Extra set of wheels in decent shape plus a spare
Drip rail looks nearly mint
Glass is basically all good other then some chipping around the driver side vent window lock
Was told the rear axle was recently serviced by Pats driveline as well as the driveshaft and I see Pats sticker on it
Master cylinder looks pretty new
Looks like a pretty new battery
Looks like newer alternator
VE looks either replaced or serviced (may or may not be a good thing I guess)
Looks like newer calipers
FASS fuel system (questions about this to follow) Came with two new extra filters too
Came with a brand new, old stock rams head from Cali
Fairly little cab/bed rust and frame appears to be good but it's oil covered so I can't be 100% sure


The bad:
I think there is OD issues. Have to confirm but when I test drove before buying it wouldn't go over about 80-90 KM and the speedo didn't work.
BUT when I drove it home from picking it up (5 min drive) the speedo worked.. so maybe there is OD? Need to plate it to really test it out.
The floor pans have small patches, nothing like my previous trucks and others I've seen.
The pinch weld on driver side for the door seal is rotted away
The rocker is dented like someone jacked the truck up by the rocker {no}
I don't care but the grille is very cracked in a few spots
The bed seems to be bolted down with new bolts, maybe even new brackets
The FASS filters are really low and ugly, but I've seen others mount them in the same place. Just stupid.
Also there is two toggle switches by the OD off button. The PO said they need to both be on for the truck to run.
The truck wont start without them on and the key won't shut it down, just the switches for the pump/s does it
Stock lift pump is just sitting there unattached
The boost tube broken off to the AFC cover
Oil pan is dented in like someone drove over a rock
Lots of leaks, told one is the rad but I can't see where exactly
The bed near the tailgate has a dent and I can see bondo in it so there may be more on the truck
Seems to be a leaking front hub


That's about all I can think of off the top of my head. I'm sure there will be more.

First questions:

Looking at the pictures, is there even an OD unit on the end of the tranny?! The rear of this 518 looks different then mine ???

What is the tetris block looking thing under the master cylinder?

Can anyone tell me anything I need to know about the FASS fuel system? Why would there be two switches?

The e brake light and ABS lights stay on, what could that be?

The dash says unleaded gas only, is this just a replacement dash or something else going on here? The vin checks out as a diesel truck.

Is the broken boost tube a possible culprit for not getting the higher speed? Are they available to buy?

Is the stock lift pump fine to be left sitting there with no lines attached?


Anything anyone can see by the pictures please tell me what you think. I can get more pictures if needed too.


Doc,

Ya the floor didn't shock me. I did replace the floor pans and rockers in my W150 years back. It wasn't horrible but not fun.
I've loved the Borgeson on my W250 for the last few years so I'm thrilled this truck already has one, they aren't cheap.
I don't know about the IP being worked on but it looks like it has been, it's got fresh looking paint on it.
Yes, it will need a good cleaning to find the source of the leaks.
 
#15 ·
yes i am pretty sure it has OD. the tailshaft would get pretty small pretty quick if it didn't. the tetris block is the proportioning valve. it balances brakes front to rear. just unplug the abs module behind the glove box and hopefully it will shut the abs and brake like off. yes the stock lift pump is fine to be left there. it is just going along for the rid at this point. i am guessing 1 of those 2 switches probably controls fass fuel system and the other runs to the red wire that connects to the fuel shutoff valve. i am pretty sure we should be able to do a bit of wiring and get rid of those switches and wire things like they should have been. i don't think that is a seal leaking on that front hub. pretty sure it is just a cap that has been beaten too many times in the wrong way. i think i got a couple used ones that are in better shape if you want

i do got to say overall it looks in really good shape. i think that thing would likely pass a safety with very little-no work. you can see someone spent a lot of money on it. i really don't see anything too concerning. let me know when you want to tackle some of that list.

it sounds like that boost tube being broken makes a huge difference to how the truck performs
https://www.dieseltruckresource.com/forums/1st-gen-ram-all-topics-93/broke-screw-but-beat-powerstroke-173329/#post1739350
 
#16 ·
2 w/d and 4 w/d trans tails are different .... look for the wire connection for the O.D. on the trans, there is the speedo one your aware of ( on tailshaft ) , then there is one near the shift shaft on trans ,( it threads in horizontally) , ( its a neutrial safety /back up lite switch) then there's another connector , a little farther rearward , connects vertically , will have 2 OR 3 wires , its O.D.( and maybe LOCK UP , if 3 wires )
 
#17 ·
The FASS system is a nice upgrade. Rather than type out the details, heres what FASS has to say;
https://fassride.com/what-is-fass/#introduction

BTW this is a good upgrade, and I would usually recommend it if it weren't so expensive. But as an FYI anyway, I went with a competing brand named, Air Dog

Ed
 
#18 ·
4x4KLOWN said:
...The FASS filters are really low and ugly, but I've seen others mount them in the same place. Just stupid.
Also there is two toggle switches by the OD off button. The PO said they need to both be on for the truck to run.
The truck wont start without them on and the key won't shut it down, just the switches for the pump/s does it...
I agree. The way these filters are mounted is pretty stupid. It always annoyed me that they didn't design a more compact or horizontal system. The PO just did a lazy install. It won't be complicated to correctly rewire your setup.
 
#19 ·
if you look in almost any filter manufactures master catalog , in the back usually , you will find filter bases for screw on filters , and fuel filters that fit them . betting they would be less expensive and quality stuff to boot . it's where a fella who designs machinery looks when he's needing simple stuff like that . custom "for" his machine isn't always a good thing.
 
#20 ·
Matt,
Gottcha, I do believe it has OD. Looking forward to a real test drive to see what's going on.
Proportioning valve, got it. Why doesn't my 91 have one?
The ABS module, that also controls the daytime running light, right? I hate those things.
Is there any chance the stock lift pump can let crap in the block? Or are the fuel lines sealed off in there?
One thing I wouldn't mind is relocating the FASS switch or disguising it to be used a theft deterrent. But two switches is a bit much for every time I turn the truck on/off.
Both hub caps looks like that, like they have been beat up or just shaped that way. But the one has fluid coming out of it slightly.
Thanks for the link on the boost tube. I just read it. People there seem to say a custom made one works better but I think depending on the price from Cummins I may just stock replace it to keep it simple.

Roy,
I'll check out the plugs/wires tomorrow and report back.

Ed,
I do remember looking in to these systems (actually the air dog) a while back. I remember people on here saying it's not really necessary and expensive. I'm glad this truck came with it already so I can see what it's all about without having to buy it myself.
I checked out that link and read through the site/watched the videos. I'll have to do some more research on it when I get the time.

Doc,
Ya I'm going to either try and tuck it up higher, move it or at build a box to go around it. It really bothers me seeing it and knowing it can get smacked or tampered with.

Roy,
Good idea. I should check that out. My local Napa are good guys, I'm sure they can help me find something cheaper then the actual FASS filters that will work.
I'm good for oil filters for years.
Pic below is one of my last Rockauto orders. They were a good price and I figure I'll always need em so I got 12 :)

I literally haven't had time to really check out the truck yet or do anything. It's still got a bed and cab full of garbage.
 

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#21 ·
your 91 does have a proportioning valve but it is the older style one in the frame. abs control module is behind the glove box bolted to the firewall. your thinking daytime running lights module under the hood. the lift pump shouldn't let anything in. if you want to you could remove it and make a block off plate to clean things up. if you move the fass system i will help you fix the wiring for it so you will never need those switches. we can also add more cigarette lighter ports if needed for extras. i figure minus well do something like that since if we are running extra power wires into the cab. i think i might have 2 used ones if they are both as ugly looking as the 1. they really shouldn't leak. it is just grease. if you want we can pull the rotors and re-pack the bearings if you want but i think if you just cleaned things up there really shouldn't be any future issues
 
#22 ·
Ohhh I see, under the hood seems like a better place for it so it stays cleaner/dryer.
And ok, that is the small black cube looking thing then for the DRL? And the abs mod is the computer looking box stamped with the Chrysler logo, right? I think I already have two of them in my stash.
Right on, I may do that one day. Easy enough to make a plate and bolt it on.
A few extra cig lighters may be good. I use them for dash cams and gps. Speaking of, I never did finnish hard wiring the dash cams in the 91. I'd like to do that one day too.
And sounds good. One day when we get some time we can check out the front end/bearing etc.
 
#23 ·
ya the cube under the windshield washer tank is the DRL module. ya i think you got 2 also. i think 1 is from that 89 we parted out. who actually needs an abs module? most just disconnect them. ya i see how much is hooked up in your 91 and figured you would probably need a few extra ports. i think you could even get away with a with a usb power adapter instead to power the gps and dash camera. sounds good. the front brakes on a 2wd are super simple

https://www.ebay.com/itm/DC-Converter-12V-to-5V-3A-Double-2-USB-Toal-Length-50cm-/132701770473?_trksid=p2349526.m4383.l4275.c10#viTabs_0
 
#24 ·
Got it! Two useless parts I can remove. Weight reduction haha
I think I'd prefer most things that are staying in the truck to be hard wired in. Like the dash cams, they may as well be permanently wired in. The usb is cool, but that would also require installing the usb end on the camera wires.

I just applied for the appraisal on the 92 online. Lets see what happens.
 
#25 ·
4x4KLOWN said:
Ed,
I do remember looking in to these systems (actually the air dog) a while back. I remember people on here saying it's not really necessary and expensive.
I agree it's expensive

Necessary? Umm that part is likely subjective. Heres what I know about them and why I bought mine. (Not FASS but Air Dog)

There are 4 features that these pumps have;
Fuel filter,
water separator,
air separator,
and fuel pressure.
A lot of people don't want or need a fancy expensive aftermarket pump for a fuel filter and water separator when a 4BT or 6BT already come with a fuel filter and water separator. Some say that the air separator feature isn't really necessary or worth the hassle and-or expense, and as for the higher pressure as required by some performance mods, you could buy a dedicated high pressure fuel pump for much less.
So why did I buy the Air Dog? Simple. I was flush with cash…… ;D

No, not really 8). I was attracted to the Air Dog pump for all of the features. It started when my original factory lift pump was found to be dead and I knew I was turning my injector pump up. I didn't want the IP to starve for fuel, so I wanted a pump that had higher pressure.
I felt that the fuel filter and water separator parts was a bonus in that, it's possible to use larger capacity filters and separators, with no clearance or access issues issues and the frame mounted location for me, made replacing filters and draining water very easy. (Theres plenty of ground clearance under my Dakota with plenty of easy access) The air separator part I felt was a necessity. If you spend time around diesels, you know that diesel fuel foams when pumped. This is also true with the fuel pump. The Air Dog (and FASS system) removes air from the fuel, and I believe it makes a performance difference.

As for the frame mounted location, theres pros and cons. Con is of course, is, it's very exposed. It could be wiped off the frame by a rock or stump. It could be submerged, and brush can catch it. I've been thinking about adding either a small skid plate under mine or run a tube under it for protection. It's also difficult to relocate. The pump needs to be close to the tank and since it's "spliced" into the fuel line which has to be lower than the fuel level (which maintains prime in the line) the FASS will be low on the frame. One thing you could do to reduce the profile of the system is use smaller (shorter) filters.

The pro side is, filtration, pressure, increased capacity with room to grow and easy access.

Ed
 
#26 ·
i am pretty sure you can get usb cables for both the dash camera and gps. thy have 2 standard sized usb power cords for stuff like that. the mini and micro type B plugs are the most common type of plug. if it takes the mini-B one i should have lots of extras since they are not as commonly used as the micro-B now.


i did that with the elcamino and they got back to me pretty quick with things.
 
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