AD100 popping fuses

Big Bore · Oct 29, 2011

Since I got truck running again after replacing the fuel pump, figured I'd start another thread on the other issue I found when troubleshooting the fuel system when I got home.

The AD is popping fuses. When I replaced it the first time the pump ran for two to three seconds then popped the fuse. Next fuse popped almost immediately. I'm getting power to the pump obviously, but something is causing a power draw. The filter has high miles, 22K or so. But would a clogged filter cause the pump to overdraw current and pop the fuse? I cant get a filter till monday at the earliest so I'm just trying to eliminate any other issues till I can change the filter.

Powerstroked162 · Oct 29, 2011

I had a similar issue with a couple FASS pumps. Got so hot it melted the fuse holder. Would pop fuses right after replacing, etc., It ended up being the actual pump itself. Not an electrical genius so I can't say why exactly, other then educated guess'

SEABEE08FX4 · Oct 29, 2011

Pump is bad, went through this with a friends truck and it ended up being the pump. Airdog warrantied it for him so you may want to check with them.

SouthFlstrokin' · Oct 30, 2011

Send it back, get a ad 150

Big Bore · Oct 30, 2011

Ran a search on AD100's blowing fuses, apparently very common issue around the time this pump was made and required pump replacement which AD would send out after having owner do a couple tests. Read a couple suggestions of checking gerotor for trash and taking cover off pump, I think those came from Pureflow techs that are active on "other" forums. I've also sent a message to techs at Pureflow on their website.

Unfortunately, I'm not the original purchaser, it was on the truck when I bought it Dec 08, pump was installed in May 08 and had about 5K on it. I have no idea how long it hasn't been working, but I'm sure it's been awhile because now that I've heard it running I know it hasn't been for a long time, which is probably what took out the Walbro. I've put about 42K on the truck since I bought it, and I'm pretty sure that pump hasn't been running for at least half that.

So, hold the phone on early Walbro death, it wasn't suicide, it was homicide. Also, disregard any earlier comments I've made about the AD being quiet, because I'm sure any pump that isn't running is silent.:doh:

In any event, worst case, it isn't under warranty and needs a new pump. I called Pureflow couple months ago asking about pump upgrades because I was concerned the 100 pump wouldn't keep up with bigger injectors, and at that time a direct replacement 150 pump was $175. The AD100 and 150 pumps are same dimensions, one is just higher rpms (2000 vs 3000) according to my owners manual.

Just not sure if I even want to deal with it at this point, don't know if I trust the AD at all, so I'm going to figure out how to bypass the AD for now. Yay, two days firewood gathering wasted.

Tom S · Oct 30, 2011

You might link Pureflow to this thread in the event they want to reply. I loved that suicide vs homicide comment.

Big Bore · Oct 30, 2011

Tom S said:
You might link Pureflow to this thread in the event they want to reply. I loved that suicide vs homicide comment.

Hopefully I'll hear back from them tomorrow.

Big Bore · Oct 31, 2011

Got a very early morning reply from Josh Smith at Pureflow.

Subject: pump
To:Big Bore
Date: Monday, October 31, 2011, 6:03 AM

How long have you had the pump?

Josh Smith

(317) 421-3180 ext. 123

[email protected]

Replied with a link to this thread as Tom suggested. It's hard to have any hope at this point just based on the question asked.

Here is my reply.

Hi Josh, thanks for the early reply.

The pump was installed in March of 08, I purchased truck in Dec 08. Pump had 7Kmi on it at that time, it now has 45Kmi, but I don't believe has been working for some time. In fact, I doubt that pump has 20K on it. I discovered the problem after my primary fuel pump went out on Saturday with only 50K on it. After installing my spare pump, I began troubleshooting to see why my primary went out and discovered the blown fuse on the AD. After installing a new fuse and hearing the pump run briefly before the fuse blew again, I am certain it hasn't been working for a very long time, probably since right after I got the truck, in fact I doubt the pump has 20K on it, and when I last changed the filter I remember thinking how quiet it was, except it wasn't running and I didn't realize it. I did some research yesterday and read on several diesel truck forums that around the time my pump was purchased there were a number of pumps blowing fuses like mine is doing and pump needed replacing. The AD rep apparently had them do some troubleshooting then sent out a new pump. I also read some of the AD reps on the forums suggesting cleaning the gerotor and/or inspecting the pump. I am hoping that it's a simple fix, but after what I read I think the motor is toast. I'm not sure what the warranty coverage is, if any at this point. If it isn't covered with reassurances this was a fluke and these pumps normally last longer than that, I'll probably ditch the setup. Not knowing the AD wasn't working and losing a primary pump over it has left me nervous about repairing and using it. Fortunately I carry a spare pump, so I wasn't completely stranded here in the Rockies where I travel long distances towing a trailer as I was on Saturday, but I did miss a window of opportunity to get firewood before the heavy snow arrives, had to roll around under the truck in the snow on the side of the road changing the primary pump, and in order to use my truck this week I will be spending the day trying to bypass the AD and probably removing it. In all I'm going to be a few days behind.

It was suggested I link you here to a thread I posted if you are interested in commenting or repping AD at the forum, http://powerstrokearmy.com/forums/showthread.php?t=8235

Big Bore · Oct 31, 2011

Well no joy from AD. Couldn't wait any longer for him to reply to my reply to his email so I called Josh at Pureflow. No warranty coverage at all as I expected, even if original purchaser sent in the registration card for Lifetime Warranty it's not transferable.

Highlights of conversation.

Josh seemed to think 3 years was an acceptable lifetime, even though actual miles at best are less than 50K, which I can confidently say it's less than half that.

Unfiltered fuel is being drawn through the pump before going through the filters. So a custom made specialty filtration system is not protected by the filters. Seriously, I almost laughed. According to Josh this causes stress on the gerotor pump and takes out the motor if any trash is drawn out of the tank. However, the guy I bought the pump from did the in tank and filler mods and cleaned the tank thoroughly when he did the AD. The tank was probably cleaner than when new based on the insanely detailed maintenance the guy did. Truck came with a log book of everytime hood was opened, extra filters on every fluid in the truck, and the date written on the filters when they were changed.

Josh offered a new pump for $175 with a lifetime warranty.

My thoughts. Pump is not reliable. Warranty is not acceptable to me. I've had entire cars, firearms accessories and tools with transferable lifetime warranties. Something as reliable as the AD claims to be with a design for high mileage trucks should be transferable. If it's not, that affects my confidence level and begins looking like a back door for the manufacturer.

I can buy another Walbro for a spare, and a prefilter head unit and filter to protect it for the cost of the AD replacement pump. With the in tank mods the air situation has been dealt with, and RR should take care of the rest.

There is no way to know when that pump quits working without doing a major inspection on it constantly, which is why it can be not running and take out the primary when you don't expect it like happened to me. So basically what I have is an expensive filter head unit with a broken unreliable pump on it causing a restriction in my fuel system.

Anyone wanna buy it?:badidea:

Tom S · Oct 31, 2011

Big Bore said:
Well no joy from AD. Couldn't wait any longer for him to reply to my reply to his email so I called Josh at Pureflow. No warranty coverage at all as I expected, even if original purchaser sent in the registration card for Lifetime Warranty it's not transferable.

Highlights of conversation.

Josh seemed to think 3 years was an acceptable lifetime, even though actual miles at best are less than 50K, which I can confidently say it's less than half that.

Unfiltered fuel is being drawn through the pump before going through the filters. So a custom made specialty filtration system is not protected by the filters. Seriously, I almost laughed. According to Josh this causes stress on the gerotor pump and takes out the motor if any trash is drawn out of the tank. However, the guy I bought the pump from did the in tank and filler mods and cleaned the tank thoroughly when he did the AD. The tank was probably cleaner than when new based on the insanely detailed maintenance the guy did. Truck came with a log book of everytime hood was opened, extra filters on every fluid in the truck, and the date written on the filters when they were changed.

Josh offered a new pump for $175 with a lifetime warranty.

My thoughts. Pump is not reliable. Warranty is not acceptable to me. I've had entire cars, firearms accessories and tools with transferable lifetime warranties. Something as reliable as the AD claims to be with a design for high mileage trucks should be transferable. If it's not, that affects my confidence level and begins looking like a back door for the manufacturer.

I can buy another Walbro for a spare, and a prefilter head unit and filter to protect it for the cost of the AD replacement pump. With the in tank mods the air situation has been dealt with, and RR should take care of the rest.

There is no way to know when that pump quits working without doing a major inspection on it constantly, which is why it can be not running and take out the primary when you don't expect it like happened to me. So basically what I have is an expensive filter head unit with a broken unreliable pump on it causing a restriction in my fuel system.

Anyone wanna buy it?:badidea:

That is a pretty darn good review of the Airdog in a Powerstroke application and not too far off from what I see for the FASS in a 7.3. I am glad you took the time to post that Frank. Are you going to tear it apart to see what failed?

Big Bore · Oct 31, 2011

Tom S said:
That is a pretty darn good review of the Airdog in a Powerstroke application and not too far off from what I see for the FASS in a 7.3. I am glad you took the time to post that Frank. Are you going to tear it apart to see what failed?

Yea I'm going to pull the setup and bypass for now. Might try to see if I can easily modify it for use as a prefilter without the pump. I'll post pics of the pump when I take it apart. Was planning to do today but last minute I need to go pic up an engine in Fairplay. Hopefully I don't smoke the fuel pump again. Light throttle I guess. Sucks because I just bought all the hoses and fittings ($250) last week to install the Terminators with quad feed and twin IPR's and was planning to do that Sunday (yesterday). :fustrate:

caladash · Nov 1, 2011

Been running my air dog 150 for over 50k feeding into a walbro. Problem free. Definitely noticeable when running. I'd be glad to buy it if the price is right.