when working on my new (to me) 02. Where to start....O.K. how about on the FASS kit I bought from Vulcan. While I don't fault anyone on the manufacturing end of the kit, I ran into nothing but problems while attempting to remove the fuel tank last weekend. From trying to remove the fill tube, to just getting the thing lowered and out proved to be next to impossible, even after removing the straps. The problem was simply that you need more altitude with which to maneuver the thing out there. I had/have no hoist, I didn't even have any ramps with which to raise up the work area for easier, more comfortable access. While I'm sure there are those around who have removed the tank successfully while the truck wasn't jacked/raised up, this big tall guy has no thoughts of attempting that again without some way to raise the truck. I buttoned the thing up and then worked on replacing the rear shocks as I had already done the front ones a couple of days before. The drivers side rear shock was a piece of cake as I have all the air tools and things needed to do that so at least the whole day won't be a waste. Shock number 2 on the other side was a bit different. Seems like Pedro (or was it Juan??) who built my truck in Mexico decided to install the bottom shock bolt the wrong way so that the suspension bar would be right in the way, preventing it's removal. While it was easy to get the cut off wheel and zip that thing in two, finding a like bolt on short notice on a Saturday proved about as fruitful as dropping the fuel tank mentioned above. Anyway, after a trip to Ace Hardware I found a suitable bolt, nut and lock washer and changed it after arriving back home.
Flash ahead to today, and my new Diablo Power Puck shows up via a UPS delivery first thing this morning. They say it'll ONLY TAKE A FEW MINUTES TO INSTALL but after all these mechanic blues I've been experiencing lately, here's a couple of observations:
Disconnect the MAP sensor electrical connector and plug in one of the connectors on the Puck, according to the pics.
How do I get my BIG HANDS back in there to do that?? How does it uncouple?? Just slide it straight back or is there a lock clip?? The only thing bigger than my hands is my head and I can't get close enough to see back there. Good thing I have (some) patience. The pictures in the directions are small enough that I'm reminded why I have to wear bifocals. What a joke!!! Worse yet is that the truck in the pics is either older or newer BUT MINE DOESN'T LOOK ANYTHING LIKE THAT !!!!!!!!!!!!!!!!!!!!!!!!!!!!
Also, I get my Dfuser brand headlight upgrade so that the low beams will stay on when the high beams are activated. Price of the upgrade?? Slightly over $50. Well, I open the package and the first observation is that there ARE NO INSTRUCTIONS INCLUDED IN THIS KIT. You have to go to their website where they have them listed as PDF files which takes Adobe's Acrobat Reader to open and view the file. I've NEVER been a fan of Acrobat PDF files but the real problem for me ocurred a couple of months ago when I bought a new computer that has Windows Vista as the operating system. I LOVE my new computer but VISTA has a couple of quirks, among them is that I have been UNABLE TO INSTALL ADOBE'S ACROBAT READER in any shape, way or form. It will NOT install for some strange reason and as someone who's had computers since 1993 and has built several of them over the years, I'm at a loss to say why (I can't get it to load). Frustrating??
Anyways, so here I set having spent over $50 on a part that the manufacturer doesn't think enough of to include a piece of paper that would have something resembling an instruction sheet included in the package. I sent them them a rather P-O'd response and have not heard back from them. I either wanted directions now or directions on how to return the merchandise.
Anyways, that's what kind of weekend this backyard wrench has been having since trying to unscrew this truck. Did I mention FRUSTRATION???????? I'm sure there are other frustrations going too but these are the main ones that I can think of right now. Instead of wrench time I think it's MILLER TIME. THIS SUCKS!!!!!!!

 

You sure you wanted to post that on the forums????

 

it's time to step away from the truck for a day, lol.

 

On the MAP sensor, there is a red clip that needs to slide about 3/16" toward the firewall with a small screwdriver then squeeze the clip (near the wires at the back, not close to the engine) and it pulls right off. I found the best way to remove the old one is to examine the new one on the chip/powerpuck. It's easier to look at out in the open.

Can't help you with the rest sorry.

 

I recommend a self-anesthetization protocol via the metabolization of a sufficient quantity of CH3CH2OHC2H5OH.

 

I feel ya on that dern map sensor. I got tired of my bro laughing at me when I was trying to get that thing undone so I made him do it

If you can find a bike/atv style lift that might be just the ticket- thats how I plan on trying to drop my tank if I ever get a round tuit.

 

Geez either thats bs or you have too much stuff memorized. Either thats alcohol or and admin should slap ya with the big stick

 

Sorry for the tech-speak... I'm cursed with an eidetic memory.


p.s. shorthand is C2H6O, or abbreviated EtOH - colloquially known as grain alchohol

 

Ok back to helping chux. Dfuser upgraded hd healinght harness:

1) Unplug the stock harness from the driver's side headlight
2) Plug stock harness into the blue plug on the upgrade harness
3) Plug the upgrade harness into the driver's side headlight. Route the harness over the top of the radiator. Unplug the passenger side headlight from the stock harness and let it hang- it will no longer be used. Plug the upgraded harness into the headlight making sure all the pins make a good connection.
4) Run the fround wires from the headlight plugs to suitable grounds.
5) Find a suitable place to mount the relays.
6) Lastly attatch the red hot leads to the positive terminal on the driver's side battery. The battery lead is fitted with a fuse and does not require an additional fuse

I'm sure there are errors and ommisions, but this might be enough to get you started.

 

Hey Chux. Dont feel too bad. You should of seen me replacing the rear shocks on my 3500 today.

My day was already going to crap at 5AM when I got up... By this time 3PM, im feeling little better and thought id be nice to the old cummins and throw some new shocks on her. Well lets just say if anymore dirt,sand,grass etc fell in my face and eyes while under the truck I was going to burn the whole thing down to the ground. Got the old ones out, just finishing up puttin the new ones in and I caught my arm on somethin sharp under the truck and tore some hide off on my left arm. Here I sit, blood runnin down my arm and I went to go pull myself out from under the truck, grabbed onto the spare tire for some leverage. And SNAP!! The cable broke and the spare tire fell and landed on my stomach, knocking the air outta me.... At this point I realized that I shoulda never gotten outta bed this mornin.... Only good of having a day like this is they only come so often, so I have a clean run of decent if not good luck coming up!!

 

Instead of dropping your tank, lift up the side of the bed. Did that when I had to pull my fuel tank module, was able to do it by myself and not risk trapping myself when a half full fuel tank rolls on top of me. Didn't have to disconnect anything except the 4 bolts on the left side, and loosen the 4 on the right.

 

Correct shorthand would be C2H5OH to signify the hydroxyle group- naturally your shorthand is correct but not useful for the longer chain alcohols.. Even in the short chain C2H6O is also Dimethyle ether

AlpineRAM

 

Thanks for the words of encouragement!! Sounds like some of you had the same kind of day I was having!! It's nice to eek out a small "victory" and get something done so you can build upon your success. But on some days, I guess I'd be better off going out and working in the yard.
There's some fine ideas there too. I like the bike lift to help get that fuel tank out. I have one of those and you're right....that'll be a BIG help when I go to drop it the next time. I had been planning on the tank being next to empty as I had been keeping an eye on total mileage for that tank of diesel. I am getting 20 mpg so 700 miles on the odometer and the tank should be empty. I had 682 miles on it when I got home that Friday night so besides running on fumes, the tank felt nice & light. The only reason I have to drop it is to drill the inch and a quarter hole for the Draw Straw on the top of the tank so I don't know if I could get away with drilling the hole without removing the tank. I'll have to study that one further.
The Dfuser harness is a great idea (it keeps your low beams on when the highs are on and in a safe manner electrical wise). Why they don't include directions....I just shake my head.
I was just frustrated that nothing seemed to be going right so yes, that's the time to step away.
Oh, I did have one thing go right but I'm puzzled at why I received 2 DIABLO PUCKS?? Even tho I only ordered 1, when I opened the box there were 2 boxes that each contained a puck. They both have the same part/stock numbers but each have a different date (of manufacture??) on the box. The only difference I can find is that one of them says "TUNABLE" whatever that means. They both have the same connectors and otherwise look the same but why there was 2 of them in the box left me scratching my head. Any guesses as to why there was 2 pucks in the box??
Again, THANKS EVERYONE for the words of encouragement and your suggestions. Hopefully the next time will go better!!
Chuck

 

Well, something GOOD to report. My friend who has small(er) hands than I do, stopped by and we got the Diablo Power Puck installed in about 15 minutes. After a test drive.....WOW!! And that's from the 50 hp puck. That'll be plenty and all I need hp wise. Anyway, something easy and something QUICK, install a POWER PUCK and you'll be smiling too!!

 

Thats 50/150. You're feeling the extra 150 lbs of torque