Time to change/add fluids to the old girl and see if we can get her running!

Adding Fluids – boy that was expensive!

• Change engine oil – 7 qts 5W – 20W Synthetic Valvoline
• New oil filter – MOPAR 090
• Add transmission oil – 1 qt ATF +4 Synthetic O’Reilley
• Fill radiator 50-50 mix Prestone/Distilled water 4 1/2 gal
• Fill Power Steering – 1 qt Prestone Power Steering Fluid
• Fill Rear End – 2 1/2 qts Super Tech Synthetic 75W-140 gear lube
• 10 gal – Chevron Premium plus 1 bottle Seafoam

Okay let’s give it a crank …

Hummmmm…. fuel pump doesn’t seem to be running …

Try several more times, good news the pump came on! Bad news, it sounds like a garbage disposal, runs for about 30 secs then shuts down… hummm try a couple of more times … no joy… arrrrrrrgh!

Tap into fuel module lines and run a long lead up to the front of the wagon so that I can bypass the Fuel Relay that is controlled by the computer, pump doesn’t run. Okay, turn key on and check to see if 12v is being provided by the relay. Yep, the computer, relay and wires are all doing their job, I have 12v going to the fuel module when the key is turned on or the engine is cranked.

Okay, final test – remove air filter and cover from the throttle body and spray ether into throttle body, then try starting the engine. Yep, engine starts and runs on the starting spray, definitely a fuel problem … groan….

Drop gas tank again, this time with 70lbs of gas in it! Clear off welding table and roll it under the wagon, set 4 jack stands on the table, set creeper on jack stands, let hoist down until fuel tank is resting on the creeper. Stand on bench, and climb into the back of the wagon through the passenger rear door, undo nuts holding the tank straps, climb back out of the wagon and lower self down to the bench, knock bench over and drop to the floor on top of toppled bench, utter many nasty words while holding knee and dancing around shop on one leg

Raise lift a leave the fuel tank on the creeper, jack stands, welding table. Pick up and move the aforementioned bench next to the welding table that is under the back of the wagon and remove the fuel module. Dry it off and take it over to the bench and apply 12v directly to the pump… no worky… toss fuel module into the trash, get in truck and drive to O’Reilley’s and buy a new module for the grand sum of $128.

Not so fast big guy…

Install fuel module, lower hoist, position tank straps and then climb back into the wagon again to tighten down the straps. Make a much better exit this time! Raise hoist with tank and move the welding table back to its home in the shop. Lower hoist and turn the key on, pump starts! Hooray, happy dance! Pump only runs for 2 secs unless you run the starter, so I shut the key off and turn it on again to prime the fuel rails. Pump starts and immediately a stream of gas is spraying out of the quick connector on the fuel rail. Shut off key, mop up the gas and then inspect the quick connect.

Looks like the spring clip that holds the connector to the fuel rail is bent and not making a good connection. Head over to O’Reilly’s and order a set of replacement clips. Of course this is on Saturday and the parts wont be in Show Low until the following Tuesday. Go back to shop, raise hoist with the idea of working on the brake lines, hummm… a puddle of power steering fluid on the floor. Must have over filled it. Clean it up and go to the back of the wagon to see what needs to be lined up to start on the brake lines. Open box from Speedway with all the brake fittings, lines etc and then head back to the toolbox to get the tubing bender, notice another puddle of power steering fluid. Seems to be leaking out of the rear of the pump, bad news, the back of the pump is supposed to be sealed. Drain the power steering oil from the system and remove the pump. Back of the pump housing is cracked and leaking oil. Get the tool to remove the pulley from the pump, while attaching the tool to the pump, it slips from my oily hands and lands on the floor, now have a four piece plastic power steering pulley.

Go back over to O’Reillys and order a Type III GM Saginaw pump and was shocked to learn that they had the Dodge pulley in stock! The pump will be in on Tuesday as well as the fuel clips.

Tuesday rolls around and I pick the pump and clips up after I went to the gym, which is right across the street from O’Reillys. After breakfast head over to the shop and replace the clip and o-ring in the quick connect, attach it to the fuel rail and try it out! Still leaking… groan, pull the fuel line off again and get out my magnifying glass. The plastic sleave in the connector which is part of the seal, has been damaged, hence the leak. Go to the internet and search for a replacement connector, no one seems to make one. I guess the liability insurance guys dont like the idea of a shade tree guy like me messing with 50 psi fuel lines. So off to the Dodge dealer to see if I can find something that works. The parts guy is really helpful, but I dont have many options. I can buy a new fuel line, or I can use my leaky one and burn the car up… okay order the damn fuel line for $119… will have it in a day or two. Once the line came in, I pulled the old one, that is attached to the transmission and replaced it. Hooked it up to the fuel rail, turned the key on and was happy to see that I didnt have another leak!

Back to the shop, lets see if we can replace the power steering pump. The GM and Dodge versions of the pump are virtually the same housing, the GM pumps is valved to 800-1000 psi where as the Dodge is closer to 2000 psi. By using the GM pump my GM A700 power steering box is happy. All that you need to do is drill out the threaded mounting hole on the GM pump to 5/16″ and it will bolt right up to the hemi block. You also need to ream out the hole in the Dodge 7 rib pulley from 5/8″ to 21/32″ to fit the shaft on the GM pump. Actually you need to ream the hole out to 43/64″ to have the right clearance. Of course there is no place in Show Low to buy a 43/64 drill so I used a 21/32 which I could buy at Ace. Bad idea as it turns out. On the 1st pump that I tried, I cracked the back of the pump when I pressed the pulley on, but didnt realize that I had. On the second pump, I heard a loud crack just as I was seating the pulley on the shaft. I turned the pump over and this time I had broke the whole back of the pump housing off. Sigh…

I tossed in the towel and got on the phone to Speed Performance and ordered one of their modified pumps with the pulley already installed.

Will up date this status soon! I hope!