Regan Brown
The FASS 95 series had a smaller thread size than its newer counterpart. The old FASS 95 pump used the FASS 2003 filter and also worked with the Fleetguard 5712, which had a 13/16 x 16 thread. The new replacement uses a 1 x 14 thread filter. The 20x1.5mm nipple that the fuel filter threads onto is threaded into the filter base.
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What You'll Learn
FASS 95 pump and thread size
The FASS 95 pump is a fuel pump with an integrated filter system designed for Cummins Diesel engines. It is a popular choice for owners and enthusiasts of Cummins-powered Dodge pickups. The FASS 95 pump has gone through some design changes over the years, which have included updates to the thread size.
The older FASS 95 series pumps had a smaller thread size. Specifically, the "Old" 95 pump, which used the FASS 2003 filter and was also compatible with the Fleetguard 5712 filter, had a 13/16 x 16 thread size. This older thread size was measured as 1-14 by some users. The fitting screwed into the filter has a size of 12mmx1.5, which is the same size as the injection pump.
The newer FASS 95 pumps feature a different nipple size, and the thread size for the new filters is not readily available. However, it appears that the new filter thread size is slightly larger than the old one. The new FASS filters have a 1" x 14 thread size.
It is important to know the correct thread size when replacing fuel filters to ensure compatibility and proper function. The FASS 95 pump with the new filter size may require a different adapter for an Auxiliary (AUX) fuel tank setup.
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Bleeding the valve above the filter
It is important to bleed the air from your diesel fuel system to ensure proper fuel delivery. Air in the fuel system can delay or prevent the diesel fuel from reaching the injectors, making your engine difficult to start, reducing the engine's power, or, in severe cases, causing the inability to start the engine.
Steps to bleed the valve above the filter:
- Turn off the fuel valve.
- Clean the outside of the filter housing.
- Install a new filter element and new gaskets. A little oil on the gasket will aid a tight seal.
- Fill a spin-on filter with clean fuel before installation.
- Open the bleed plug on the filter closest to the fuel tank.
- Open the fuel supply valve so that the fuel is available to the filter and pump.
- Pump several times until a full flow, without air bubbles, escapes from the bleed plug holes.
- Close the bleed plugs after all air is removed from the fuel tank, filters, settlement bulb, and fuel pump.
- Try the engine; if it doesn't start or runs poorly, you may have to bleed the injection line.
- Loosen injection lines at the injectors about one turn. The use of two wrenches will prevent the binding or twisting of steel lines.
- Crank the engine until all air is forced out and fuel is present.
- Tighten the injector lock nut one at a time to tell by sound which cylinders are firing properly.
- Run the engine until it runs smoothly.
- If the engine does not start or there are indications that air remains in the fuel system, repeat the bleeding process at the fuel filter or fuel injectors.
- If you encounter any difficulties or persistent issues after repeating the bleeding process, consult a professional diesel mechanic or contact the manufacturer for further assistance.
Note: It is recommended to determine how air entered the fuel system to ensure it does not re-enter after completing the bleeding process. Additionally, consider replacing the fuel filter if it is old or approaching the end of its life.
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Priming the fuel filter
While there is some debate on the necessity of priming the fuel filter, as some claim that the CR engines are self-priming, there are several methods to prime the fuel filter of a Cummins engine.
One method is to turn the key to the "on" position several times, which will activate the fuel pump to fill the canister. However, this only runs the lift pump for 3-5 seconds. A more effective method is to "'bump' the starter", which will run the lift pump for 25-30 seconds. This can be done by cycling the key on for 3-5 seconds, then off, and repeating this process 4-5 times. Another method is to pour some fuel into the aux filter before reinstalling it, which will speed up the self-priming process.
It is also possible to prime the fuel filter by filling the filter with fuel first. If this doesn't work, the fuel line at the top of the intake can be cracked, and a primer can be used. If that still doesn't work, the engine can be cranked with the fuel injectors cracked until fuel starts coming out, at which point they can be tightened.
Additionally, when replacing the water separator filter, it is recommended to add a little fuel to the new filter.
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Using a filter wrench
To change the fuel filter on a 1995 Cummins 5.9L engine, a filter wrench is required. The filter wrench will help to loosen the old filter and install the new one.
A filter wrench is a tool specifically designed to grip and turn oil filters and fuel filters, allowing them to be removed or tightened. They are typically used when the filter is too tight to be removed by hand.
Before beginning, ensure you have the correct size filter wrench. For the Cummins 5.9L engine, a 92.6mm 4-tab fuel filter wrench is required. This size wrench fits the fuel filter on Dodge Ram diesel engines. The wrench can be operated using a 3/8" ratchet or a 24mm/15/16" socket or wrench.
Step 1: Locate the fuel filter. On the 1995 Cummins 5.9L engine, it is located just below the brake booster.
Step 2: Using the filter wrench, grip the old fuel filter securely. Ensure that the wrench is properly engaged with the filter to avoid slipping and potentially damaging the filter housing.
Step 3: Turn the wrench in the counter-clockwise direction to loosen and remove the old fuel filter. Be careful not to overtighten the wrench, as this can damage the filter housing.
Step 4: Once the old filter is removed, inspect the water separator at the bottom of the filter. If it is still in good condition, it can be reused.
Step 5: Prepare the new fuel filter by filling it with fuel and attaching the water separator.
Step 6: Using the filter wrench, begin to tighten the new fuel filter by turning it in a clockwise direction.
Step 7: Tighten the filter to the specified torque as shown on the canister. Do not over-tighten, as this may cause leakage and damage to the housing.
Step 8: Reattach any wires or components that were disconnected during the process.
Step 9: Start the engine and let it crank for a few seconds before firing it up.
It is important to note that some older Cummins engines may have different thread sizes, so it is always recommended to check the specific thread size of your fuel filter before attempting any maintenance or repairs. Additionally, when using a filter wrench, always exercise caution and ensure that the wrench is securely engaged with the filter to avoid slipping and causing damage.
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Threading the fuel filter
First, locate the fuel filter. It is usually found below the brake booster in a 1995 Dodge Ram 2500. To access it, you might need to remove the two nuts holding the brake master cylinder to the booster, providing more room to work.
Next, use a filter wrench to remove the old fuel filter. Before removing it, take note of the thread type, as it is critical to match the thread type of the new filter. The thread type is typically NPT or NPTF, which are tapered threads commonly used in plumbing connections in North America. These threads require sealant, and you should use liquid or paste-type sealants to avoid clogging.
When installing the new fuel filter, ensure that the threads are properly sealed. Apply the appropriate thread sealant to the male thread tip and female valley. Be sure to select a sealant that is chemically resistant to fuel or oil running through the line. Avoid using regular old gas-resistant Teflon tape, as it may break free and cause clogging issues.
After applying the sealant, carefully thread the new fuel filter by hand, ensuring it is securely attached. Reattach any wires or hoses that were previously connected to the old fuel filter.
Finally, before starting the engine, fill the new fuel filter with fuel to avoid trying to pull fuel from the tank initially. Crank the engine for a few seconds before starting it, and ensure that all connections are secure and there are no leaks.
By following these steps, you can safely and effectively thread the fuel filter of a 1995 Cummins engine, ensuring a proper seal and avoiding any potential issues caused by incorrect threading or sealants.
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