Lost boost first month owned...now found after a month of troubleshooting....

[LPreddie]

I apologize in advance for this long post, but it was theraputic............

This post is to convey my high_Low-high as a new DC owner. How helpful this list has been. And to tell A few unique things I found during troubleshooting......

My friend (on his 3rd DC) convinced me to switch to a DC when I needed to sell my SRW F**D for a DRW. I am not partial to any brand; just need it to do its job (tow camper w/trailer). I bought the DC because of price and bombing potential. Honestly, I was not impressed with the stock power, my 95 Pstoke F**D felt like it had bigger biceps.

I started bombing with a goal in mind ( read TDR post for weeks). I even followed the recommeded order to be safe. gauges, filters, cat, kdp, plate, gsk.

Needless to say by the end of my first month of ownership I was beyond happy. With the new found power, I could not have asked for more.

Memorial wknd w/camper (heavy) we drove approx. 1000 miles in 4 days from E. Washington up and around the Olympic Peninsula and back. The truck drove nice, lots of winding roads, over mountins, and downshift to 3rd to easily pass RV's going below the speed limit (love that boost).

I don't know when it happend, but I slowly noticed with full throttle I could barely hold 45 on hills and I did'nt dare try to pass anyone ( or I was now the one in everyone's way). The next day it only got worst, i would pull over to let traffic by. I wondered if something broke or was it the elevation.

I will shorten this up some..................

I hope I did not create a bad impression of DC truck as I found myself under the hood anytime we stopped for fuel or camp. I could not find anything (by the way piers used a special glue on the air bleed screw as it does not turn). I was so depressed......
It really took the Grin off my face on the way home. Once home I refused to drive it for anything as it was even more of a dog in town.

Toubleshooting......... I checked for leaks reptd, even removed some lines. Bought plumbing to do pressure test. chk fuel filer chk cam plate if loose, chk gov lever, chk wastegate, overflow spring Nothing.

On my trip home the boost did return for about 2 minutes.
I spend late night reading post and eve's doing check again.

I remove the overflow valve and took it apart and stretched the spring to about twice its length ( I had already stretched w/no change). I drove 2 block and back and I had BOOST again. Whooohoo. I reconnect boost hose and no boost. Remove boost hose and still no boost. Ordered new overflow valve from piers (dealer 110 and Piers 55). Got part install no boost. Dang! Depressing. Start troubleshooting all over. Checkes all again R and R AFC and intake over and over.

TDR list exhausted, called piers, suggest lift pump (oh! that's what that does?). Ordered. Got and installed (it takes patience) no change. Dang! Depressed....

Wife says, "you're going to have a new truck soon if you keep replacing parts with no change" That's just all I need on top of a one month old truck that can't get out its own way. Geeeessssseee.

Please don't let it be the injection pump.....Please.... Up til 3-4am studying post ; how the AFC works and its adjustments. Chk gov lever for the 6th time. It hits perfect and flush with bottom of plate although some on list suggest adj higher. Solenoid lift n hold test not work, troubleshoot but not sure. Gov lever does not move up full distance. Call piers, is there a height adj for lever? mine will not move all the way up plate. Piers explains, lever moves up with rpm of pump and engine speed, not by adjustment. But the lever is contacting as per the diagram. The wear marks on lever (not metal but oir residue) suggest the lever somehow has cycled under the plate.

Ok perform the gov lever adj ( at least I might learn something).
Set above bottom just incase it is somehow getting under plate.

Hot Dang!!!! Stella got her "boost" back. I was so happy, I almost forgot I was on a test drive, drove so far I almost couldn't find my way home (could'nt think clearly).

I am now back in business, just need to adj for excess smoke (starwheel as I did adj everything troubleshooting).

I hope there is something in here that may help others. It was very helpful and encouraging to see that many others have fought the low/lost boost problem for great lengths of time so maybe my post will encourage you to keep trying and not give up. In the process you will learn so much about how diesels operate it will build confidence to tackle future repairs yourself.

FWIW. I had to do all the work outside in sun on the rear lawn/grass as i have no garage, but I am building one.


Stella's new man.........