Diesel Truck Batteries

volvo hybrid drive 22 Diesel Truck Batteries

Installing a Regulated Return Fixes the 99 to 03 Ford Powerstroke Dead-head Fuel Rail Issue

Ford produced some award winning diesel truck designs between 1999 and 2003 that for the most part boasted overall improvements for the Powerstrokes. However, in Ford’s attempt to lower fuel tank emissions by preventing fuel heated in the fuel rails from being returned to the fuel tank, they had created an entirely new problem. This is a common problem in Ford Powerstrokes, referred to as “dead-heading”, by diesel enthusiasts which gets it’s name from the process feeding fuel into the fuel rail head.

Each injector gets its fuel from the fuel rail head, unfortunately, this “rail” has no outlet and ultimately starves the injectors of fuel. The lack of fuel to the injectors causes them to run inefficiently while increasing noise. Fuel held in the rail can also become heated because it is no longer flowing which causes additional injector noise and wear. Ford attempted several fixes but the problem persisted until the 6.0 Powerstroke Diesel Engine was introduced in 2004.

The 1999 to 2003 Ford Diesels were and still remain tremendously popular trucks. This means that there are many people suffering from “dead-head” fuel system problems. These problems can cause poor mileage, loss of power, and noisy operation. Many of the effected trucks can also exhibit a noticeable knock at idle. Engines that exhibit a knocking sound also usually experience a loss of power combined with poor fuel economy. These symptoms are caused by air being drawn into the fuel system and getting trapped there.

Attempting to convert this type of engine to VO in order to solve dead-heading is not really a suitable solution. Because the fuel is dead-headed in the fuel rails, any fuel that remains in the rails must be consumed in order to make room for the incoming fuel that displaces it. So, if you are running on Diesel and wish to switch the engine to VO you must run the engine long enough to consume the fuel in the rails before any VO can be burned. This is actually more of an issue when switching from VO to Diesel because the engine will need to run for 15 minutes or more on Diesel before it can be shut down safely.

The Fuel Rail Crossover or regulated return is a much more suitable solution and was made specifically to solve the ‘deadhead’ fuel rail issue found in the 99-03 Powerstroke engines. The Fuel Rail Crossover, (FRx), connects the two heads and allows the air to return by another path rather than forcing it through the injectors preventing them to do their job efficiently. This product was designed as a true bolt on system which eliminates hack fixes that require the need to cut the return line and use compression fittings. The FRx is also machined to provide from 72 psi depending on the type of spring used in installation which is perfect for stock parts or upgraded performance parts. This fuel rail crossover system completely eliminates air in the fuel system which in turn provides a smoother ride, quieter idle, less cackle, better throttle response and increased fuel injector life. It also comes in at a fraction of the price when compared to other regulated return systems that do the same thing, making it a no-brainer.

About the author: Clay Note is the owner operator of Riffraff Diesel Performance Parts, one of the internets premier diesel performance parts websites. Clay specializes in Ford 7.3 diesel and Powerstroke Performance parts for Ford Diesel Trucks.

Source: http://www.isnare.com/?aid=1090307&ca=Automotive

Frequently Asked Questions

  1. QUESTION:
    can a car jump start a diesel truck with 2 batteries?

    • ANSWER:
      Very likely not, uness you can leave it hooked up to charge up for a long time (hours) before you try starting it. The diesel truck has two high-drain batteries in it to provide enough amperage to run the glow plugs and start the high-compression diesel engine. One car with one set of jumper cables will never provide enough juice.

      The tow trucks use two sets of jumper cables, connected to both batteries in their truck (a diesel as well) to jump start diesels. OR they could have a second battery along for the ride in a gasoline truck, specifically for starting diesels.

  2. QUESTION:
    Why does my diesel pickup truck have 2 batteries? is it still 12 volts? could i jump something if i needed to?
    Any info that you could tell me would be helpfull. it is a 2004 chevy silverado 3500 (duramax diesel 6.6L)

    • ANSWER:
      It has 2 batteries, – because one battery can not provide enough cranking amps to start the engine (dependably)! The batteries are connected in “parallel”, – which means that you still have the 12 volts the same as everybody else! I might add, – if you need to replace these batteries (one or both), – get the highest “amp output” battery that can possibly be mounted in the provided place! You need all the amps possible when the temperature “really gets down there!”

      Another warning here, – do not try to continue to start engine when batterys are very low, – you can burn out the starter, as it actually draws more amps cranking “slow” with reduced voltage, – than cranking fast with proper voltage! This is a 0 to 0 “mistake”!!

      Be aware though that the “cheap jumper cables” you buy everywhere are about useless to actually “jump start the truck! They are capable of carryng 10 to 30 amps usually!, – Your truck probably requires around 450-500 amps on a “nice warm day”, – maybe 750 amps on a “cold day”,- when the temperature is well below “0″! So you can leave jumpers hooked up with another vehicle running, and “warm up the batterys”, and charge them some (if possible), – but the cables will quickly start to “smoke” when you start cranking! You have really fat insulation, but thin wires! Maybe 8 gauge (on most cables)! So if you want to be prepared for really “Jump starting” your truck, – you are going to have to go to somewhere that sells the jumper cables that the “big truck drivers use”! These cables have “00″ gauge wire or bigger, — (1/2″ dia wire,– or bigger, – as compared to maybe 3/16″ wire). These will probably cost you in excess of , so you will want to store them carefully and take care of them! You don’t want to be buying them often!

      Note: actually one battery will not dishaarge into the other – unless the second batery is not good anymore! The bigger battery will provide somewhat more amps while cranking, but if the “450 amp battery” – is capable fo putting out 450 amps yet, — and the “new 550 amp battery” is fully charged, — they will still put out 12 volts, and the amperage required to crank the starter will still remain the same!

      Technically the starter will draw a little more amperage out of the “bigger battery”. The “Cranking time” will still be longer than two of the same sized (good) batteries would be!! When the charging system brings the back up to full charge, the larger battery will charge slightly longer (or faster) than the smaller one! However they will both charge to proper levels, and then “taper off” to low “maintainance rate” from there on!

      Or simply put you will not have any problems! The only thing you have to worry about is putting in batteries too small to do the job,- in which case they will go “down” very rapidly! A smaller battery againast a bigger battery decreases cranking time!

  3. QUESTION:
    Why does a cummins diesel truck have 2 batteries?

    • ANSWER:
      There are two main reasons
      1st–there are fast acting double grid heaters in the intake that can pull up to 120 amps while starting.
      2nd- reason in order to build up cylinder pressure ( heat is used to ignite the fuel); and build up fuel pressure; the engine needs to be able to turn a min. of 250 rpm’s while cranking—with out dropping below 10.0 volts ( 9.8 volts min voltage needed while cranking the computerized systems in order for it to function, and the min voltage needed to pull and hold in the shut down solenoid on the non-computerized ones ). Because this is a 12 volt system and the amount of amp draw from the battery– it was easier to put in two batteries then one huge one.

  4. QUESTION:
    On my diesel dump truck I have 3 batteries. It won’t start, shoule i replace all 3 or just one?

    • ANSWER:
      All three should be replaced at the same time.

  5. QUESTION:
    diesel truck completely dead, no lights or anything, both batteries show charge everything is tight, no jump?
    It was cold out and the truck was cranking slow, my bro charged both batteries in the truck at the same time now everything is completely dead. I tried jumping it and got a dash light on for a couple seconds then completely dead again.?

    • ANSWER:
      First check your batteries because cold weather will finish off a sick battery.

      If the battery indeed took a charge and is showing 12 plus volts you may have a short in the wires or a bad solenoid over the starter.

      Have someone shaking the wiring while your trying to start it to see it you get power.

      If you got power but its not turning over then hot start it by turning the key to the on position, while the key is on connect the two posts on the starter together with a screwdriver. That completes the circuit by bypassing the solenoid. If that starts it, it’s the solenoid is bad.

      If you try that and you have power to the dash but hot starting doesn’t turn the motor then you have a bad starter.


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