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Fuel Pressure Drop Under 1/2 Tank

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Josh0726

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Discussion starter · #1 ·
2016 Durango RT RWD. This past year, I completed a swap of my stock 5.7 for a forged 6.4L stroker. As part of this project, I also had the shop install a Hellcat fuel pump. The motor has been running great but I have been chasing a fuel-starvation issue. When my fuel level is at 50% and I turn left through an intersection, the engine will sputter until I complete the turn and straighten out. When the fuel level is closer to 30%, I lose all power and the engine will shut off. To verify I still had about 5 gallons of fuel left in the tank, I limped it to the station and put around 19 gals in to fill it back up.

I had the shop pull the tank again to confirm the fuel basket is moving freely. Since the HC fuel pump is taller than the RT pump, WWE swapped out the fuel line on top of the pump with a longer one to reduce the bend radius and prevent the hose from collapsing.

At this point, we cannot determine the cause of the low fuel pressure when the fuel tank level is low.
Does anyone have any experience with this issue?
 
#2 ·
It sounds like the secondary pump on the passenger side of the tank is failing.
 
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Discussion starter · #3 ·
I am struggling to find much information on that unit. Do you know if there is an actual pump on the passenger side of the saddle tank? I am seeing a product called the fuel tank sending unit with level sensor but this unit does not include a pump, is this the part you are referring to? I appreciate the help with this. This issue has been bothering me for a while now.

5145587ac

2011-2021 Mopar Level Unit Module Kit, Secondary 5145587AC | Mopar eStore
 
#4 ·
Did your shop do both Hellcat pumps?

the Hellcat system is a dual pump setup, and it takes a lot of fab work to fit it into a non Hellcat vehicle

when my boost a pump fails (some point far in the future hopefully), I plan to install this. It’s a single pump, good to support 800hp, with a return less setup, and is drop in fitment

kpmfuelsystems.com

KPM 800HP IN-TANK FUEL MODULE (JEEP GRAND CHEROKEE / DODGE DURANGO) | KPM Fuel Systems

Part No.: Jeep Grand Cherokee (2012-2025): AUP-KPMJD800-P Dodge Durango (2012-2025): AUP-KPMJD800-P The KPM 800 hp Module simply replaces the existing OEM fuel module to deliver cool, dense fuel to support power up to 800 hp on the race track as well as delivery for perfect manners in day-to-day...
kpmfuelsystems.com kpmfuelsystems.com
 
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Discussion starter · #5 ·
I only had them swap out the single driver side pump for a 525lph. The KPM pump you linked looks interesting and a solid option for the future but I am curious if it would solve the issue I am having.
I am still researching a replacement for the transfer unit on the passenger side.
 
Discussion starter · #6 ·
I just ordered a replacement fuel tank auxiliary sending unit that is installed in the passenger side of the saddle tank. It seems the function is to transfer fuel from the passenger side to the driver side. I am suspecting there may be a small hole in the transfer line, causing a loss of suction when the fuel level is under 1/2 tank.

Thanks for the guidance and we will see if it fixes my issue!
 
#7 ·
I don't think the module will come with the line which connects it to the main fuel pump

Image




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See attached PDF's for the full details.
 

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#8 ·
Yes, that is what that pump does. Plan on replacing the transfer hose too because you could be right about a hole in it.
 
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#9 ·
Tin Foil Hat said:
Yes, that is what that pump does. Plan on replacing the transfer hose too because you could be right about a hole in it.
Click to expand...
The aux fuel pump module doesn't have a pump, it's just a pickup with supporting components.

I know the Hellcat has a dual pump setup, but am not sure if that 2nd pump is located on the aux module?
 
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Discussion starter · #10 ·
I replaced the auxiliary fuel pump module. Unfortunately, it did not correct the issue. I am not sure what direction to go from here. I am considering replacing the fuel basket and all of the lines surrounding the pump unless someone has any suggestions.
 
#12 ·
I would replace both sides since you have it down. That's just insurance.
 
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Discussion starter · #13 ·
Yep, probably should have done that... but I didn't. I will replace the basket and lines after I drop everything again. Since they were installed last year, I didn't initially think of replacing the basket and lines.
 
Discussion starter · #14 ·
To close out this thread. I purchased the KPM 1000hp system and installed it. I am seeing around 60psi fuel pressure and the fuel starvation issue under 1/2 tank is completely gone. I even, carefully, ran it down to about 1/8 tank with no issue so it seems to perform like the OEM system.
The KPM system also pulls less current than the hellcat pump so it doesn’t require any external wiring upgrades and I am no longer melting fuel pump fuses.
 
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Josh0726
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