Changing Fuel Filters: 1995 Dodge Diesel 4X4 Guide

Changing the fuel filter on your 95 3500 Dodge Diesel 4x4 is a relatively straightforward task that can be done at home, saving you a costly trip to the dealer. Clean fuel is essential for a healthy diesel engine, and fuel filter replacement is a major maintenance item that should not be neglected. This guide will walk you through the process of changing your fuel filter, ensuring your truck's fuel system stays in tip-top shape.

Drain the fuel

To drain the fuel, you will need to attach a hose to the water drain valve, which is located at the bottom of the filter housing. Place the other end of the hose in a catch pan or bucket to collect the fuel. Open the valve and allow the fuel to drain completely. This process will help remove any debris or water that has built up in the filter, which can cause contamination and performance issues if left unchecked.

For a 6.7L engine, the fuel filter housing is located on the driver's side of the engine, below the intake manifold. The drain hose is positioned above the front differential housing. To access it, you may need to extend the hose by attaching a 1/2 inch hose mender and a section of clear chemical tubing. This will allow you to drain the fuel into a suitable container without making a mess.

Be sure to only insert the barbed fitting of the hose mender as much as necessary into the filter housing drain hose, as it may become stuck and create a permanent connection. Once the fuel has drained, you can proceed to remove and replace the fuel filter.

Remove the filter housing

To remove the filter housing on your 1995 3500 Dodge Diesel 4x4, you'll need to first locate the fuel filter housing. It should be on the driver's side of the engine, near the firewall.

Now, fit a 1/2" drive extension into the square receptacle on top of the fuel filter lid. Using a 1/2" ratchet, loosen the lid until you can remove the filter element and lid by lifting them up and out. If you can't use the square drive, you can also use a 1-1/8" (29mm) socket on the lid.

Be careful to avoid any cables when lifting the filter element and lid. Tilt the assembly at a 45-degree angle to allow fuel to drain back into the filter housing. This will prevent air from entering the fuel lines or lift pump, which can reduce performance.

With the filter element and lid removed, turn the assembly over and locate the 8 retaining tabs holding the element in place. Gently pry these tabs outward and lift the element to remove it. You can also take this opportunity to remove the old o-ring from the lid.

Now that the filter housing is empty, you can proceed to install the new filter.

Replace the filter

The first step is to drain the fuel. Attach a hose to the water drain valve at the bottom of the filter housing and place the other end in a catch pan. Open the valve and let the fuel drain.

Next, remove the filter housing. For the 5.9L engine, simply remove the cap and lift the filter out. For the 6.7L engine, first unplug the water-in-fuel sensor and then lower the canister and filter out through the bottom of the vehicle.

Take out the old filter and inspect the inside of the cap for any debris or contaminants. If you find any debris, clean the cap before installing the new filter.

Before installing the new filter, lubricate the canister O-ring with engine oil and insert the new filter into the cap. Reinstall the filter/cap assembly into the housing and torque to 22.5 ft-lbs (30.5 N-m) with a socket.

For the 6.7L engine, locate the engine-mounted fuel filter housing on the driver's side of the engine block, below the brake fluid reservoir. Connect a tube to the drain hose at the bottom of the housing and place the other end in a drain container. Open the drain valve and let the fuel drain.

Lubricate the new filter housing lid O-ring and the outer fuel filter seal with engine oil. Remove the old filter and install the new one. Reinstall the fuel filter housing lid and torque to 22.5 ft-lbs (30.5 N-m).

Finally, prime the fuel system by cycling the ignition to the "RUN" position (without starting the engine) 10 to 12 times.

Prime the system

To prime the fuel system of your Dodge Ram after changing the fuel filter, you can simply cycle the key without starting the engine. This should be done 10 to 20 times, according to some sources, or 2 to 3 times according to others. You will hear the fuel pump running. The book for your vehicle may specify a particular number of times to do this.

Some trucks may take up to 12 key cycles to prime the system. You can also apply power to fuse 70 with the ignition off, which will activate the fuel tank lift pump. About 30 seconds of this should be enough to prime the system.

If you have a 2010-2018 6.7L Cummins, you can turn the ignition to 'run' without attempting to start the engine. Do this 2 or 3 times to prime the system before cranking the engine.

If you have a 1998.5-2002 2nd Gen Dodge 5.9L 24V Cummins, you can bump the ignition a couple of times to fill the housing and then crank the engine.

If you have a 2012 6.7L Cummins, you can cycle the key 3 to 4 times to prime the system after a filter change.

Check for leaks

To check for leaks in your 1995 3500 Dodge Diesel 4x4, there are a few methods you can use. Firstly, it is important to take precautions to prevent any risks to your health and home when looking for a fuel leak. Do not smoke while working on the vehicle, and park it outside, away from any appliances with an active pilot light.

Now, to begin your inspection, raise the vehicle and support it on jack stands. Using a flashlight, carefully trace the fuel lines from the tank to the engine, looking for any signs of leaks. These signs may include spots with an accumulation of dust and road grime, wet spots or streaks, or clean spots where fuel has washed away grime. If you find evidence of fuel dripping from a structural component, follow it to discover the source of the leak. Remember that gravity and wind pressure can affect the path of the fuel, so it may be running along multiple components before dripping.

If you are unable to locate the leak through a visual inspection, there are specialised products that can help. You can add a dye to your fuel that will glow under fluorescent or ultraviolet light, making it easier to identify the source of the leak. Brands such as Cliplight Incorporated, Spectronics Corporation, and Interdynamics offer these dye products. Simply add the dye to your fuel, run the engine to leak some treated fuel, and then inspect with a handheld light.

For more hidden leaks, you can use a leak detector device, which has a probe that you can insert into less accessible areas. This device can detect the presence of compounds within both gasoline and diesel, helping you pinpoint the source of the leak.

It is important to repair any fuel leaks as soon as possible to prevent potential fire hazards and damage to other components, such as rubber tires and bushings, painted sheet metal, and plastic parts.

Frequently asked questions