Replacement for AirDog?
I've had nothing but problems with my 200 GPH AirDog II. Just trying to buy the right thing involved 3 trips to Jefferson City so we've faced nothing but hassles from the start. Once we were finally on the road we barely made it from St. Louis to Salt Lake City and had to have a new AirDog shipped to us within days of installation.
Got lucky for a couple years only having to swap filters and motors. I didn't get the warranty info from the shop that installed it so I'm now having to buy replacement parts. They sold me a filter last time that doesn't even fit. Almost every time we've called for support we're talking to a different person because the last guy isn't there anymore. The shop we've been going to used to be a dealer but had the same issues and doesn't deal with the anymore.
Originally pumps would have little pressure and lose that over a few months. Barely maintained 10 psi for years. Aside from swapping in new motors, Pureflow has sent us the other part with the bearings in it, and we've even dropped the tank. We finally bought a decent motor for it this last time that puts out strong, consistent pressure averaging 50-60 psi, dropping occasionally to 30 something under load and peaking near 80. The motor sounds louder but low RPM torque feels stronger, smoke is decreased, and fuel economy has averaged nearly 2 mpg higher, even when hauling cattle.
This new pump that finally runs strong has been having other electrical problems resulting in melted fuses, relays, and wires. The local shop discovered problems in the original AD wiring harness. First they swapped in new pigtails but those melted. They tried soldering wires directly and those have held but we're still melting relays and fuses. By melted I mean soggy wads of plastic.
The local shop put an amp gauge on the wires and saw erratic draw going from 5-10 amps to 20 amps. Electrical load seems to change independently of the consistent fuel pressure. The shop says the issue is within the pump drawing more amperage than the system is made to handle since the wires coming out of the pump are only 14 gauge. We could upgrade everything else but those 14 gauge wires will then probably end up melting. The pump obviously sometimes draws more than the 20 amps the circuit is built for.
I've spent thousands in shop fees over the years trying to get the AirDog to be reliable so it is time to replace it. I've read FASS system can have the same issues with wiring and I can't risk another several hundred dollar fuel pump problem. The reason I went to an electric lift pump was because I went through 14 mechanical pumps in 2 years. I assumed it was no longer possible to get a good mechanical lift pump even from dealerships. The shop I'm talking to says he's pretty sure he can get an Allied mechanical pump that would be better than a Carter that should be good for 60,000-70,000 trouble free miles. He said the new mechanical pumps no longer come with the primer button so you have to crack the injectors.
If I go back to a mechanical lift pump I'll need to come up with a new filter system. Any recommendations for something I could mount to the frame that would be easy to swap with filters easy to find when traveling? Something with a water drain? I'm also wondering if I should look into a pump and filter combination from a WVO vendor. I'm expecting those systems have been far more thoroughly tested and are perhaps much more durable since they're designed for greater viscosity. Any experience or recommendations regarding a WVO system? Not sure I want to do all of the collecting and filtering, I just want something that won't have me calling a tow truck on a monthly basis.
Just out of curiosity, has anyone managed to have years of trouble free use with an AirDog? I've had nearly everything checked; filters, lines, fuses, relays, wiring harness, no air or fuel leaks, replaced motors and even the entire assembly. I hate now that I have a strong running pump I can't keep it running. I'm done.
2000 Excursion: 1994 5.9, 913, DDP3s, Garrett Stage 2, ported head & exhaust, custom intake, fire rings, ARPs, 17.5*, AirDog 2/200, HXPB, BTS 4R100, PCS TCU, '06 F-350 suspension & axles, ARBs, PSC steering, 16,800 Atlas Winch, 37" Geolander A/Ts, 18x9 ATX Slot, BD X-Monitor, water injection