The FASS Dodge Replacement Pump (DRP 02) is a high-performance diesel fuel lift pump designed to replace the factory transfer pump in 1998.5–2002 Dodge Cummins 24V diesel trucks. This pump aims to address the common issues found in original equipment (OEM) lift pumps, such as poor fuel delivery and frequent failures. With a flow rate increased by 33% compared to the stock pump, the DRP 02 offers improved fuel pressure and efficiency for the VP44 injection system. It is engineered for easy installation, utilizing the factory mounting points and wiring harness, making it suitable for both professional and DIY installation.
This article provides a detailed guide based on the information from official installation manuals, technical troubleshooting notes, and user-submitted parts lists. The goal is to present a clear, factual, and actionable resource for U.S. users considering or performing the DRP 02 installation on their 1998.5–2002 Dodge Cummins 24V diesel trucks.
Overview of the FASS DRP 02 Pump
The FASS DRP 02 is marketed as a direct replacement for the factory lift pump in 1998.5–2002 Dodge Cummins 24V diesel trucks. It is positioned as a cost-effective alternative to the more comprehensive FASS high-performance fuel systems, offering the reliability and performance of the brand without the additional complexity and installation time. According to the source documentation, the DRP 02 is designed to deliver a flow rate of approximately 65 gallons per hour (GPH) at 9 pounds per square inch (PSI), which is a 33% increase over the stock pump. This improved flow rate helps ensure consistent fuel delivery to the VP44 injection pump, which is critical for engine performance and cooling.
The pump is installed in the stock pump location and uses the factory wiring harness for power. One of the notable features of the DRP 02 is its ease of installation, which can be completed in under 30 minutes by a novice mechanic. The installation process requires replacing the stock steel fuel line from the pump to the filter housing with the rubber fuel line and fittings included in the kit. It is important to note that the DRP 02 is not compatible with waste vegetable oil (WVO) or biodiesel fuels, and it is not recommended for use with retrofitted in-tank lift pumps without the use of a fuel sump kit or suction tube.
Installation Requirements and Components
Before beginning the installation of the FASS DRP 02, it is essential to gather all the necessary components and tools. The source material from installation forums and technical manuals lists several key items that are either included with the kit or must be sourced separately. These include:
Fuel Sending Unit Area Components:
- Russel 640830 – 3/8 o-ring flare/-6AN male tank line adapter
- -6 female to 3/8 Pushlok Barb
- New O-Ring from a master kit
Pre-LP Filter Area Components:
- NAPA 3270/Wix 33270 filter with 3/8 ends (141 Micron, free flowing)
- 3/8 hose clamps (2, included with pump)
Pump Area Components:
- FASS DRP-02 High Performance Diesel Fuel Pump
- M12x1.5 ORB /-6AN Male fittings
- -6 female / 3/8 Pushlok Barb
- 1/8 steel plate and pre-drilled angle welded bracket
- NAPA Gasket material (to insulate aluminum pump to steel mounting plate)
Primary Filter Area Components:
- AcDelco 12642624 Duramax Kodiak style filter head with Primer, WIF sensor, and heater
- ACDelco TP3018 filter (98% at 4 Micron with water separation, built-in heater, primer, and WIF sensor)
- M14 ORB / -6 JIC Male 90* adapters
- M10x1.5 ORB to 1/8 NPT Female 90* fitting for fuel pressure sender
Injection Pump Area Components:
- Electric fuel pressure gauge (already installed in some setups)
In addition to these components, users must ensure that all factory fuel lines and fittings are compatible with the DRP 02 system. It is also recommended to replace the fuel sock in the tank with the included pre-LP filter to ensure optimal fuel flow and filtration.
Step-by-Step Installation Guide
The installation of the FASS DRP 02 can be broken down into several key steps, as outlined in the source documentation and installation manuals. These steps are intended to guide users through the process of removing the stock fuel pump, preparing the mounting area, and installing the new DRP 02 pump with the appropriate fittings and components.
Preparation and Safety:
Before beginning the installation, ensure that the vehicle is in a stable position and that the fuel system is depressurized. It is recommended to disconnect the battery to prevent any electrical accidents during the installation process. Additionally, have all the necessary tools and components ready to avoid delays.Removing the Stock Fuel Pump:
Locate the stock fuel pump, which is typically mounted in the driver’s side frame rail near the fuel tank. Disconnect the factory fuel lines and electrical connections, and carefully remove the pump from its mounting bracket. Take note of the orientation of the original components to ensure correct installation of the new pump.Preparing the Mounting Bracket:
The DRP 02 requires a mounting bracket to secure it in place. If the stock mounting points are not sufficient, an optional relocation bracket is available. This bracket moves the pump closer to the fuel tank, reducing the distance the pump must pull fuel from and allowing fuel to be delivered under pressure. This improves the pump’s efficiency and reduces strain on the motor.Installing the New Fuel Pump:
Mount the DRP 02 pump onto the prepared bracket using the included bolts and gaskets. Ensure that the pump is securely fastened and that all electrical connections are properly seated. The pump should be connected to the factory wiring harness, which provides power to the unit.Connecting Fuel Lines and Fittings:
Replace the stock steel fuel line with the rubber fuel line and fittings included in the DRP 02 kit. Connect the fuel line from the pump to the filter housing, ensuring that all connections are tight and leak-free. It is important to use the correct type of fittings and clamps to prevent fuel leaks and ensure a secure connection.Installing the Pre-LP Filter:
Install the pre-LP filter (such as the NAPA 3270/Wix 33270) in the fuel line to provide additional filtration before the fuel reaches the pump. This helps prevent debris and contaminants from entering the pump and causing damage. Secure the filter in place and ensure that the fuel flow is unrestricted.Mounting the Primary Filter Head:
If the vehicle does not already have a high-quality primary filter head, install the AcDelco 12642624 Duramax Kodiak style filter head. This filter includes a water separator, primer, and WIF (Water in Fuel) sensor, which helps protect the engine from water contamination and allows for easier priming of the fuel system. Connect the filter head to the fuel lines using the appropriate fittings and ensure that all connections are secure.Testing and Bleeding the Fuel System:
Once the installation is complete, it is important to bleed the fuel system to remove any air pockets that may have formed during the installation process. This can be done by running the fuel pump and allowing fuel to flow through the system until all air is expelled. Check for any leaks or loose connections and tighten as necessary.Final Checks and Reassembly:
Reconnect the battery and test the fuel pump to ensure that it is operating correctly. Monitor the fuel pressure gauge (if installed) to verify that the pump is delivering the expected flow rate. If the pump does not start or if there are issues with fuel delivery, refer to the troubleshooting steps outlined in the source documentation for further guidance.
Troubleshooting Common Issues
Despite the straightforward installation process, users may encounter common issues that can affect the performance of the FASS DRP 02. The source material includes several troubleshooting steps that can help identify and resolve these problems.
Fuel Pump Not Starting:
If the pump does not start, check for power and ground connections. Ensure that the fuse is properly installed and that there are no direct shorts in the wiring harness. If the fuse pops immediately upon installation, inspect the wiring for damage or corrosion. In some cases, applying dielectric grease to the fuse holder can help prevent future corrosion and electrical issues.Fuel Pump Stopping or Cycling:
If the pump stops or cycles on and off, it may indicate a problem with the internal motor or wiring. To troubleshoot this issue, slightly loosen three of the four bolts on the motor or pump base while holding the motor in place. Start the unit and slowly torque the bolts diagonally to 110 inch-pounds. If the problem persists, it may be necessary to contact a dealer or technical support for further assistance.Air in the Fuel System:
Air in the fuel system can cause the engine to run poorly or fail to start. To address this, use the 5-gallon bucket test as outlined in the source documentation. Place the suction line in a bucket of fuel and attempt to start the truck. If the engine starts normally, the issue may be with air entering the fuel line through components in the tank. If the engine still does not start, bleed the fuel system up to the injection pump to remove any remaining air.Fuel Pump Sounds Like It Is Turning 'Off' and 'On':
This issue may indicate a problem with the internal wiring or motor. Check for any melted or burned wires and inspect the connections to the harness. If the motor runs for a short period before stopping, it may be a sign of an internal short or faulty component.
Compatibility and Limitations
The FASS DRP 02 is specifically designed for 1998.5–2002 Dodge Cummins 24V diesel trucks and is not recommended for use with modified or high-horsepower applications. The pump is engineered to function as a stock replacement, meaning it is optimized for the factory fuel demand of the VP44 injection system. Users with retrofitted in-tank lift pumps should ensure that a fuel sump kit or suction tube is installed to provide a reliable fuel supply to the DRP 02.
It is also important to note that the DRP 02 is not compatible with waste vegetable oil (WVO) or biodiesel fuels. These alternative fuels can cause damage to the pump and may void the warranty. Additionally, the pump is not designed to work with certain aftermarket modifications that alter the fuel flow characteristics of the system.
Warranty and Support
The FASS DRP 02 comes with a one-year warranty upfront, which can be extended to four years if the user submits the required warranty information. This extension is typically done through the manufacturer or an authorized dealer. In the event of a defect or performance issue, users should contact FASS technical support for assistance. The source documentation recommends reaching out to Gillett Diesel Service Technical Support at (801) 571-7780 for further guidance on troubleshooting and repair.
Conclusion
The FASS DRP 02 is a reliable and cost-effective solution for replacing the factory lift pump in 1998.5–2002 Dodge Cummins 24V diesel trucks. With its improved flow rate, ease of installation, and compatibility with the factory wiring and mounting points, it offers a practical upgrade for users seeking to improve fuel delivery and reduce the risk of common pump failures. By following the step-by-step installation guide and troubleshooting common issues, users can ensure that their DRP 02 operates efficiently and reliably. As with any mechanical modification, it is important to adhere to the manufacturer's guidelines and seek professional assistance if needed.