Stalls in 5th gear at 50+ mph - Defender Source
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  #1  
Old March 26th, 2013, 02:02 PM
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Cool Stalls in 5th gear at 50+ mph

I have a 85 D90, 300 TDI, LT77.
It's been running perfectly over the last 1,000 miles, but recently there have been problems approaching 50 mph on the highway. Every gear (1-4) works great (acceleration, RPMs etc), until i shift it into 5th and hit about 45-50 mph. The power/gas starts to sputter and goes dead. I hit the gas pedal and there's no response - so i end up coasting back to 35-40 and shift it into 4th gear, and it works fine again.

Could it be the fuel filter, air filter, turbo...? It seems like there's no deisel getting to the engine...


thanks
mike
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  #2  
Old March 26th, 2013, 02:14 PM
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Can't help, but I think I saw your truck about a month ago parked on Washington. Is your truck like a seafoam green (pulling that color from the gf's color spectrum)? I was in a black D90 if you saw it.
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  #3  
Old March 26th, 2013, 02:24 PM
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Ya, that's me. Sea-foam green doesn't sounds so cool though, maybe "light hunter green" works better. I didn't see your black d90.
Let me know when there's another local meetup - sometimes i feel like i'm alone in the massive parking lot of jeeps - and bringing up my D90 in conversation to my gf or friends at a bar results in blank stares and crickets... ha
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  #4  
Old March 26th, 2013, 02:26 PM
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I would look into the fuel supply first. First stop, check the lift pump. Just disconnect the discharge line and crank over the engine. You should get a good flow of fuel. If that is OK, change the fuel filter and test again.

Is the fuel supply system setup as per a stock 300TDI or different?
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  #5  
Old March 26th, 2013, 03:14 PM
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Pretty sure the fuel system is all stock and old. My fuel-filler neck and tank are both original and look to be on their last legs. The rest of the engine/hoses/electrical/cooling have all been redone. I'll have to check my lift pump as well - haven't considered that - I'm not yet savvy with fixing fuel systems, but i guess i'll have to start learning... thanks
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Old March 26th, 2013, 03:24 PM
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Quote:
Originally Posted by Mike_D90 View Post
Pretty sure the fuel system is all stock and old. My fuel-filler neck and tank are both original and look to be on their last legs. The rest of the engine/hoses/electrical/cooling have all been redone. I'll have to check my lift pump as well - haven't considered that - I'm not yet savvy with fixing fuel systems, but i guess i'll have to start learning... thanks
Lift pumps have a high failure rate so it should always be the first place to check.

Are you saying that the fuel system is stock 2.5NA? If so, you should be fixing that. The fuel filter is not suitable for a TDI and spill return setup is wrong, not allowing for purging of air from the system. If it is not correct, the easiest option is to get a Stanadyne FM-100 and plumb in as per a 300TDI.
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Old March 26th, 2013, 03:51 PM
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I can't imagine that the whole system is pre 300tdi (2.5). I know the filler neck and tank are from 2.5. But I think the fuel filter has been upgraded. Maybe I should just redo it with a new Stanadyne FM-100 anyway. There's nothing like a steep learning curve...

Thanks for the great info!
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Old March 26th, 2013, 03:54 PM
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Might as well post a photo of the fuel filter and piping.

I believe the saying is "Land Rover: Turning drivers into mechanics since 1948".
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  #9  
Old March 26th, 2013, 04:32 PM
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http://s1285.photobucket.com/user/miketran2/library/

Here are some pics - of my rusty filler neck, engine, and fuel filter.
I welcome the feedback!
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Old March 26th, 2013, 04:41 PM
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OK, that is the proper TDI filter and I believe it is plumbed correctly.

Don't go anywhere dusty or wet with that air filter...
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  #11  
Old March 26th, 2013, 04:45 PM
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Quote:
Originally Posted by Mike_D90 View Post
http://s1285.photobucket.com/user/miketran2/library/

Here are some pics - of my rusty filler neck, engine, and fuel filter.
I welcome the feedback!
Doesn't look too bad - my initial thought was particulates choking off the flow - but your description doesn't quite fit. Sedimenter? The pics clearly show a non standard mounting setup, could be hose collapse when under a heavy draw?
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  #12  
Old March 26th, 2013, 04:50 PM
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Quote:
Originally Posted by Mike_D90 View Post
I have a 85 D90, 300 TDI, LT77.
It's been running perfectly over the last 1,000 miles, but recently there have been problems approaching 50 mph on the highway. Every gear (1-4) works great (acceleration, RPMs etc), until i shift it into 5th and hit about 45-50 mph. The power/gas starts to sputter and goes dead. I hit the gas pedal and there's no response - so i end up coasting back to 35-40 and shift it into 4th gear, and it works fine again.

Could it be the fuel filter, air filter, turbo...? It seems like there's no deisel getting to the engine...


thanks
mike
Yep fuel flow. Have you changed the filter recently ?
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  #13  
Old March 26th, 2013, 05:17 PM
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I just bought a new fuel filter but haven't put it in yet.
Considering the potential non standard mounting set up, would it benefit me to just go ahead and install a new Stanadyne FM-100 (like John mentioned)? If it's not broke dont fix it, but not sure what's broke!
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Old March 26th, 2013, 05:20 PM
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There does not look like there is anything wrong with the fuel filter installation. I would give the lift pump a check first.

1) Disconnect wire from injection pump.
2) Pull line off of side of filter housing that comes from the lift pump.
3) Stick line in bucket and have assistant crank engine. You should get a good flow of fuel.
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  #15  
Old March 26th, 2013, 05:20 PM
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Install the filter and try the truck. Fill the filter with diesel before screwing it on. I fill mine with atf when I change them.
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  #16  
Old March 26th, 2013, 06:14 PM
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right on - i'll let you all know what happens...
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  #17  
Old March 26th, 2013, 08:12 PM
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I've always filled diesel filters with ATF.
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Old March 27th, 2013, 03:40 AM
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I'm new here. Why would one fill a new fuel filter with ATF?

Mike.
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Old March 27th, 2013, 03:14 PM
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Ya i'm with you - filling your fuel filter with ATF sounds like a bad practical joke. It actually helps the engine to put Automatic Transmission Fluid in the fuel lines?
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Old March 27th, 2013, 05:02 PM
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Quote:
Originally Posted by Mike_D90 View Post
Ya i'm with you - filling your fuel filter with ATF sounds like a bad practical joke. It actually helps the engine to put Automatic Transmission Fluid in the fuel lines?
Google is your friend.

I stated what I do, not reccomended on newer electronic diesels but on old mechanical systems yes. Tdi's are 1950's technology. My advice was to use diesel.
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