Replacing Fuel Filter On '96 Dodge Cummins: Step-By-Step Guide

Changing the fuel filter on a 96 Dodge Cummins is a relatively straightforward task that can be completed in a few simple steps. First, you will need to drain the fuel from the filter housing by attaching a hose to the water drain valve and routing it to a catch pan. Once the fuel is drained, you can remove the filter housing by unplugging the water-in-fuel (WIF) sensor and lowering the canister. Be careful when handling the filter, as it will be full of fuel. After removing the old filter, simply install the new filter, replace and lubricate the canister O-ring, and prime the system by cycling the key 10 to 20 times without starting the engine. This will allow the low-pressure fuel pump to fill the new filter and purge the system of air.

Drain the fuel filter housing

To drain the fuel filter housing of a 96 Dodge Cummins, first, locate the water drain valve at the bottom of the filter housing. Attach a hose to the nipple and route it to a catch pan. Open the valve and drain the fuel.

You can also drain a small amount of fuel by unscrewing the WIF sensor. Place a small drip pan under the filter to catch the fuel.

Once the filter housing is drained, you can remove the housing and take out the old filter.

Remove the water-in-fuel (WIF) sensor

To remove the water-in-fuel (WIF) sensor, you will need to first place a small drip pan under the filter to catch any fuel that spills. Next, unclip the WIF wire from the wire harness by leaning over the fender in a position that looks like you're hugging the brake master cylinder. Then, carefully unscrew the WIF sensor to drain a small amount of fuel. Close the sensor back up and reposition the drip pan to catch any more drips. Now, you can unscrew the filter and rest it down in the little pocket between the frame and motor mount. You will then need to reposition your hands and sneak the filter through the wires to fully remove it.

Remove the filter

To remove the filter from your 96 Dodge Cummins, you will need a flexible strap-type oil filter wrench. You can get one at an auto parts store for around $7.

First, place a small drip pan under the filter to catch any spills. Then, carefully unhook the electrical connection from the water sensor that connects to the bottom of the filter. Now, slip the strap onto the filter from the bottom. The filter will be full of fuel, so be careful not to spill.

Next, you will need to unscrew the filter. Twist it towards the front of the engine, and then pull it out by hand. You will need to manoeuvre it through the wires of the WIF (water in fuel) sensor. Once the old filter is out, you can transfer the WIF sensor to the new filter.

Install the new filter

Now that you've removed the old fuel filter, it's time to install the new one.

First, ensure that you have a new O-ring ready to replace the old one. The new filter should come with a set of new O-rings. Lubricate the new O-ring with engine oil and place it on the threaded stud. Next, transfer the Water-in-Fuel (WIF) sensor from the old filter to the new one. Tighten it slightly, but not too much.

At this point, you have two options. You can either fill the new fuel filter with clean diesel and put it back in, or you can put the new filter in empty and prime the system later. If you choose to fill the filter, use a funnel with a long clear tube attached to it. Slowly pour diesel into the funnel and run the tube down to the new filter. Once the filter is full, carefully lift it up and screw it back into the housing.

If you choose to put the new filter in empty, simply screw it into the housing without filling it. After you've done this, you will need to prime the system. To do this, turn the ignition key to the "Start" position briefly and then back to "Run". The electric lift pump will run for about 20 seconds. Repeat this process once or twice more, and then try to start the engine. If the engine doesn't start after 10-15 seconds of cranking, repeat the priming procedure.

Once the engine is running, let it run for a few minutes and check for any leaks. And that's it! You've successfully changed the fuel filter on your 96 Dodge Cummins.

Prime the system

To prime the system, you need to get the electric lift pump to run for more than a few seconds to get the filter canister refilled with fuel. This can be done by turning the ignition key to the 'Start' position briefly and then back to 'Run'. The electric lift pump will run for about 20 seconds. Repeat this once, then try to start the engine. If it doesn't start after 10-15 seconds of cranking, repeat the priming procedure again.

Another method is to manually prime the system by pressing the small rubber button on the lift pump, which is located just below the oil filter on the side of the engine. It takes about 100 pushes on the prime button to fill the filter.

A third method is to pressurise the fuel tank. This can be done by using a modified fuel tank cap with an air hookup to add pressure to the tank. Then crack the bleed screw on top of the plate where the fuel filter attaches, and once you get some fuel out of the bleed screw, the system is primed.

If you are priming the system after changing the filter, make sure you have replaced and lubricated the canister O-ring.

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