FASS DDRP 04

Installation Manual

For specs and other info, please see our FASS DDRP information page.

The FASS DDRP Doge Direct Replacement Pump was designed and manufactured by FASS to solve a know flaw in the fuel delivery system in the 1998.5 to 2002 Dodge Ram trucks equipped with the Cummins Turbo Diesel motor. Dodge manufactured approximately 450,000 trucks with a poorly designed fuel lift pump. Eliminate this problem now by installing a FASS DDRP Doge Direct Replacement Pump for your 1998.5 to 2002 Dodge Ram.

A similar fuel delivery problem exists with the 2003 and 2004 Dodge Ram trucks equipped with the Cummins Turbo Diesel motor. This problem has also been address by the engineers at FASS. FASS has now released the FASS DDRP 04 to solve this problem. Get a FASS DDRP 04 today for your 2003 and 2004 Dodge Ram.

The FASS DDRP 04 works on all Cummins powered Dodge Ram Trucks from Model year 2003 to the end of 2004. The DDRP 04 will work on the 2004.5 Rams with the 325/600 Cummins 5.9L.

FASS DDRP 02 for 1998.5 to 2002 Dodge RAM

FASS DDRP 04 for 2003 to 2004 Dodge Ram

 

DDRP 04 - DIRECT DODGE REPLACEMENT PUMP INSTALLATION INSTRUCTIONS

The FASS’s DDRP 04 series is a complete replacement for the stock lift pump (2003 – 2004 Dodge)

The FASS DDRP 04 will be the last Fuel Pump you buy for your Dodge Truck.

The FASS DDRP 04 is mounted in a different location the OEM Pump and will not work with retrofitted in-tank pumps. Estimated Installation time is 1.5 hours.

Note: Banjo Bolt Mesh Screen is contained in the covered wire connector.

Included with DDRP:

• DDRP
• MC-990, Banjo Bolt Mesh Screen
• Frame Bracket
• 3 Frame Bolts/Self Tappers
• 3 Mounting Bolts
• 3’ of 3/8” Fuel Line
• 2 Banjo Fittings
• 2 Banjo Bolts
• 4 Banjo washers
• Quick Disconnect
• Hose Clamp
• Fuel Pump Plate
• Fuel Pump Plate Fitting
• 90° Fuel Line Fitting
• Wire Extension
• Heaver Pressure Spring
• Extra O’Ring

Needed:

• Angle Drill and Drill Bits
• Air Ratchet & Sockets
• Metric Wrenches
• Allen wrenches or sockets
• Razor Knife

FASS DDRP 04 Installation Step 2.

Checking for clearance locate the Frame Bracket with the DDRP attached between the driver’s side frame rail and starter. While holding this assembly in place mark the 3 mounting holes to the frame.

FASS DDRP 04 Installation Step 3.

Drill 3 pilot holes at the locations marked in the previous set for the Frame Bolts.

FASS DDRP 04 Installation Step 4.

Using an air ratchet screw the Frame Bolts into the pilot holes with the Frame Bracket in place.

FASS DDRP 04 Installation Step 5.

Spray WD-40 on the push lock portion of the banjo fitting and on the inside diameter of the fuel line before inserting the push lock into the fuel line. Assemble this banjo fitting to the outlet port of the DDRP using the banjo bolt and 2 washers.

Note: Before next step spray some WD-40 into the inlet port of the pump (or comparable), to help prevent gear wear while priming.

FASS DDRP 04 Installation Step 6.

Assemble the previously assembled fuel line to the outlet port of the DDRP using a banjo bolt and 2 banjo washers, one on each side of the banjo fitting. Tighten the banjo bolts with the fuel line aiming up and to the rear of the truck just clearing the mounting plate.

FASS DDRP 04 Installation Step 7.

Using the 3 mounting bolts secure the DDRP to the Frame Bracket.

FASS DDRP 04 Installation Step 8.

Attached to the back side of the fuel filter is the factory fuel pump. Unplug the factory fuel pumps wire connection and remove the 4 allen head socket bolts. Now remove fuel pump from filter housing. Note: There should be an o’ring located in the inlet port of the fuel filter when the fuel pump was removed. If not inspect the factory fuel pump where the outlet port of the fuel pump seals to the inlet of the fuel filter, if located here insert into inlet port of fuel filter.

FASS DDRP 04 Installation Step 9.

Install the Fuel Pump Plate Fitting into the Filter Plate.

FASS DDRP 04 Installation Step 10.

Apply oil to the outlet port of the Filter Plate, this is the part that enters into the inlet port of the filter. Carefully insert Filter Plate into the inlet port of the filter housing. Secure the Filter Plate using 2 of the 4 allen head bolts which held the factory fuel pump in place.

FASS DDRP 04 Installation Step 11.

Now route the fuel line from the outlet port of the DDRP to Fuel Pump Plate Fitting and cut taking into account that the 90° Fuel Line Fitting will attach to this fitting.

FASS DDRP 04 Installation Step 12.

Using the same procedures as in step 5 insert the 90° Fuel Line Fitting into the opposite end of the fuel line attached to the outlet port of the DDRP. Now secure this fitting to the Fuel Pump Plate Fitting.

FASS DDRP 04 Installation Step 13.

Remove the factory feed line to the factory fuel pump.

FASS DDRP 04 Installation Step 14.

With intensions to measure and cut the remaining fuel line route it from the inlet of the DDRP to the steel feed line addressed in the previous step. Cut to proper length and install banjo fitting in one end (remember procedures covered in step 5) and install the Quick Disconnect in the other end securing it with a hose clamp.

Review Before Completing Next Step.

Very Critical - only insert the screen ¼” into the banjo bolt, leaving about ¾” of an inch exposed

FASS DDRP 04 Installation Step 15.

Assemble the previously assembled fuel line to the inlet port of the DDRP using a banjo bolt and 2 banjo washers, one on each side of the banjo fitting. Tighten the banjo bolts with the fuel line aiming up and to the rear of the truck just clearing the mounting plate.

FASS DDRP 04 Installation Step 16.

Connect the Quick Disconnect Fitting to the steel factory fuel line disconnected covered in step 12.

FASS DDRP 04 Installation Step 17.

After everything is good and tight you can now plug the DDRP into your factory wiring harness using the Wire Extension.

LOW FUEL PRESSURE ISSUE WITH DDRP

After installing your new DDRP and you find that the pressure is lower than required (Below 12 – 14) You will find a small pressure spring, and new o-ring included in the installation kit.

• Remove the DDRP from the vehicle.
• Position the DDRP in the horizontal position with the square mounting plate facing in the upwards position.
• Remove the 3 mounting screws holding the plate to the pump assy. After removing the mounting plate you will find, an o-ring seal, a small spring, and small check ball under the spring (do not remove the check ball)
• Replace the spring and O-ring. Reattach the mounting plate, paying close attention as to not pinch the sealing o-ring. Retighten the mounting screws to 55 inch lbs. Reinstall DDRP on the vehicle. This new spring will increase the psi about 5-6 lbs.

KLM stocks a complete line of FASS Fuel Pumps and related products. Please call us to place an order for FASS Fuel Pumps or visit our online store (www.klmstore.com) to buy FASS fuel pumps and FASS fuel pump accessories. We have the FASS DDRP & FASS DDRP 04.