I'm going to try to describe my truck's issue as completely and thoroughly as possible, so bear with me with the wall of text

When I first bought my truck, the rear tank was the primary tank and the front tank was inoperable. I was told it might be the fuel filter, so I replaced that with no luck. The truck would only start on the rear tank, but after it was warm and the ambient temp was cooler, it would idle on the front tank, but soon after I would get a check engine light.

No big deal, I just used the rear tank. The only thing that was kind of weird was that it seemed to take a few more revolutions than normal to start the truck off the rear tank. I started noticing the rear tank was filling the front tank, so I set out to either replace the front pump or single it out.

Just after winter, I ordered $200 in suspension parts (radius arm brackets, leaf spring hangers, shackles and bushings, etc.) and decided to remove my bed to do all of the work. While I was there, I thought about getting a junkyard fuel pump, but I ended up getting a brand new front pump from AutoZone to the tune of around $140.

After the install, I primed the pump a few times, and she started right up! The slow start issue seemed to be gone.

Since then, the truck runs great, and compression is good on all cyls (160-165 each). I only use the front pump anymore, because I think the rear pump is getting weak, and the rear tank has a slight leak near a strap. Unfortunately, I started having some weird fuel issues recently..

First issue: I went to a friend's to work on his car, and when I hopped in the truck to start it again, it decided not to start. I turned it over a bunch of times, but no luck. Popped the hood, checked the normal stuff, found nothing wrong. Got back in, tried to start it again, and it started without issue like nothing happened. Weird.

Second issue: I was on the highway, about 65-70mph in 5th, heading out to check out a Jeep (now I own it , 1980 CJ-7, but that's a different story), and all of a sudden it was like i hit a brick wall. the truck lurched back and forth once or twice like it was out of fuel. After that, it ran and drove fine to go look at the Jeep, and drove home 40 miles without issue.

Third issue: After a workout, I went to start the truck, and the same thing happened to me as the first issue. Didn't want to start. I switched the key off, turned the switch to the rear tank, turned the key to on, heard the rear pump kick on, then switched to the front tank and the front pump turned on as well, so it appeared the switch was doing its job. Popped the hood, no issues, went back into the truck and instead of letting the starter turn a few times, I just barely blipped it with the key. It spuddered like it had fuel, and after one more time of trying to start it, it started right up like there was never an issue.

Fourth issue: After the second no-start issue, I went out to the truck after a few hours when it was cold. I tried to start it, and the starter wouldn't even engage. I heard a 'thunk' sound when i pressed the clutch it, like the solenoid was wanting to turn the starter, but there wasn't enough juice, and when I didn't depress the clutch, it didn't make the 'thunk' sound, so I figured the clutch switch was working. After a few times of jiggling the key, the starter decided to turn and it fired right up.

Fifth issue: Just last night, I was heading home, lugging in 3rd around 30mph, and the truck did the same lurching thing like it was out of fuel. Again, it drove home perfectly fine after that.


So now my question is, what gives? Also, between all of these highlighted issues, I have put miles on the truck without any issue. I've even towed cars and my Jeep with my tow dolly, all without any hiccups (well, I blew a power steering line the other day, but that was an easy fix).

I'm confused as to why I'm having some sort of intermittent fuel issue? Also, before anyone says basic tune up, I've replaced:

Distributor cap and rotor
Spark plugs and wires
Air filter
Breather filter
etc.

all within the last 3,000 miles or so, so I don't think they are the culprit. I haven't noticed any check engine lights since I replaced the front fuel pump, and before I did, it would only turn on when I tried to turn on the front pump.

If there is a common factor between the no-starting events, the truck was cold and the ambient temp was hot. Since I bought it, the truck has always wanted to start more quickly when it was cold outside than when it was warm, which I thought was odd. When the truck is warm, it starts very quickly at any ambient temp.

Does anyone have any ideas? It just came to my mind that I haven't really checked out the fuel rail pump, but I haven't been able to find a part # for one in stores.

Any help would be seriously appreciated. I love my truck but she's cold-hearted

 

Anytime I have a vehicle that exhibits the symptoms that you describe I suspect an electrical connection or voltage issue.
On my 94 the fuel pump failed on the PO and he replaced it. About a year later he had an issue of hard starts and I helped him track down the culprit which turned out to be a burned contact on the electrical connector to the tanks fuel pump.
I would also check the tank and dash grounds along with the relay in the fuse box under the hood. The selector switch and inertia switch should also be checked.

Fuel contaminants can also cause weird problems so put some Berryman's B12 (or other like product) to clean up the fuel system.
Although i buy some parts in the "zone" I usually go to Napa for the critical parts. Most of the time the price difference is small and if it isn't there is a reason.
YMMV
rikard

 

This is SPOT ON advise given here by rikard.

I had a similar condition in my 94' and it turned out to be the tank selector switch in the dash failing and then finally dieing causing a no start/no run.

Good advise given here on things for you to check.

Bob