Truck died while driving

drakon543 · Feb 28, 2020

^x2
never leave anything to chance when doing the pain in the ass jobs.

th3 shifty · Feb 28, 2020

Ok, This is good, and bad, first the good, finally got that damn tank out, one of the tank strap bolts was just spinning, had to remove the rear bumper and weld that nut, then got the bolt out.

the bad, drained about 12 gallons of gas out, removed the unit, complete. Then I look in and see a totally separate float level sitting in the bottom???

seems this thing has been repaired before and they didn’t take the time to get the level out and just replaced it. I believe this was also causing the level on the unit to read high,

well that’s one part I didn’t order, the pump and new strainer came today via Amazon Prime. Found the correct sending unit on amazon so that will be here tomorrow

willxfs · Mar 4, 2020

Everything work out ok with the new pump?

OR VietVet · Mar 4, 2020

Yes, an update would be appreciated. Thanks in advance.

th3 shifty · Mar 5, 2020

Yep, got a complete new sending unit with float level, and filter sock, started right up

th3 shifty · Mar 5, 2020

Dropping the tank isn’t a hard job on the 2dr. What made it a pain was that I one of the nuts on top of the bolts just spun, wasn’t able to get it off, had to remove the tow bar, then had to remove the bumper.

GM decided to use a ****** nut insert clip. I had to weld the nut to the clip. I also found that the wiring harness near the weather pack had been rubbing. One of the wires showing through and slightly oxidized so I clipped that section out and spliced in a new wire.

I also ran a new ground for the harness as the old area was corroded as well.

OR VietVet · Mar 5, 2020

th3 shifty said:
Dropping the tank isn’t a hard job on the 2dr. What made it a pain was that I one of the nuts on top of the bolts just spun, wasn’t able to get it off, had to remove the tow bar, then had to remove the bumper.

GM decided to use a ****** nut insert clip. I had to weld the nut to the clip. I also found that the wiring harness near the weather pack had been rubbing. One of the wires showing through and slightly oxidized so I clipped that section out and spliced in a new wire.

I also ran a new ground for the harness as the old area was corroded as well.

Nice to get in there and not only replace but see and repair the wiring, run a new ground and weld that stupid ass nut in place. Thanks for the update.

willxfs · Mar 5, 2020

Yes, thanks for the update and pictures. It's interesting to see how the pump on your 1996 rig looks very similar to the pump set ups for the old TBI rigs. The pump that I have on my 1998 rig looks quite a bit different with the pump housed in a plastic cylinder of sorts. Glad your rig is back up and running.

th3 shifty · Mar 5, 2020

Here’s a few pics of the bolts I had to weld. These are the bolts that the tank straps go into. Poor design on these.

OR VietVet · Mar 6, 2020

Cases like this is when you sometimes try and take a wrench that you don't care about that much, go buy a Japanese made wrench if need be, and you bend/grind it to try and fit thru that hole and hold the nut to remove that long bolt. PITA to have to remove all that for the access.

wjburken · Mar 6, 2020

PNW VietVet said:
Cases like this is when you sometimes try and take a wrench that you don't care about that much, go buy a Japanese made wrench if need be, and you bend/grind it to try and fit thru that hole and hold the nut to remove that long bolt. PITA to have to remove all that for the access.

Yep!

I have a cheap wrench that I bought at a local auto parts store when I was in college that was custom bent to get at a nut on the back side of the frame to remove a frame brace so I could replace the starter on my 1983 Caprice. I sold that car back in 1996 but still have the wrench and it has come in handy more than once.

OR VietVet · Mar 6, 2020

In my tool boxes over the years I had my catch all drawer for all the nuts, bolts, fasteners, screws, washers and special bits and pieces that I dug thru when needed. I had every type of brake hardware known to man in there. I also had a section for "SPECIAL" made tools that came in very handy. I also had jumper wires of different gauges and lengths with small alligator clips and male/female spades and connectors for testing power and ground circuits. All those jumper wires were always in the same drawer as my different 12 volt test lights.

th3 shifty · Mar 6, 2020

Yeah there wasn’t any way i was getting a wrench on it, the nut had sunk down just enough to go below the metal flange but would just spin below it. Instead of wasting more time on it, just took the bumper off.

horrible design on those things, don’t know what GM was thinking using those

OR VietVet · Mar 6, 2020

In something like that where the spring loaded captured nut has broke loose from the spring steel and the spring steel is now sprung up to where a box end or open end would not snake in there, I have used a distributor wrench and when I snaked it in that hole I could hopefully push up and over the end of the bolt and then pull down hard to hopefully collapse the spring steel enough to get around the 6 point nut and then get that bolt spun out of there. Fat chance I know but I have gone to extremes to save time before.

th3 shifty · Mar 6, 2020

Ok.... this sucks, truck was running great last night and all morning, did about 10 miles or so. Came 3pm had to pick the kids up from school, hopped in the truck, got about a mile from home and it died while driving.

pulled over, cranks and wants to fire but just dies. Now I can’t hear the fuel pump prime at all. I leave it there and walk home to get my other car, went to Vatozone and grabbed a new fuel pump relay, just Incase.

changed the relay, still no prime on the pump. Took a look at the fuse, which is ECM-B, fuse is good, in fact all fuses are good.

kinda lost on this one,

OR VietVet · Mar 6, 2020

May not be fuel though. Do you have spark? Check fuel pressure.

Adventure for the kids though.

th3 shifty · Mar 6, 2020

Well I can’t hear the pump prime when I turn the ignition on, nothing. So something is telling the pump it’s not on.

haven’t checked the spark, I had to leave the truck where it was, will try and bring it home tomorrow. I hope it’s not a dead pump, the brand was spectra

this is the exact unit I’m using
https://www.rockauto.com/en/catalog...fuel+&+air,fuel+pump+&+housing+assembly,10147

OR VietVet · Mar 6, 2020

Sorry, but when given a choice we always recommend AC Delco. At least I do anyway.

th3 shifty · Mar 7, 2020

Yeah I would have but rockauto only lists this spectra, complete system for 2dr Tahoe’s, the 4 door uses a different system.

OR VietVet · Mar 7, 2020

This is what I found for a 96 2 door Tahoe from Spectra: https://www.rockauto.com/en/moreinfo.php?pk=3957021&cc=1061356&jsn=2264&jsn=2264

This is what I found for a 96 2 door Tahoe from AC Delco: https://www.rockauto.com/en/moreinfo.php?pk=90717&cc=1061356&jsn=2270&jsn=2270

This is the complete assembly from Spectra: https://www.rockauto.com/en/moreinfo.php?pk=1042807&cc=1061356&jsn=2279

I found this at Amazon to go along with the AC Delco pump that I just listed:
https://www.amazon.com/Dorman-692-1...r_1_3?keywords=25027414&qid=1583561472&sr=8-3

Truck died while driving

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