95 D1 - Was driving on interstate at about 80 - suddenly lost power for about 5 seconds and then it came back.

Got home. Turned truck off - wouldn't restart.

No noise from fuel pump when key is turned to on position.

Checked the fuel pump fuse and it was blown. Replaced it. Truck wanted to start but then blew again. replaced again and then it started up. Have started it about a dozen times (and driven) since.. so far so good.

Other odd thing - the gas gauge needle is above the F mark. (Higher than when the tank is normally full).

I also swapped the fuel pump with a know good one from my other D1 - (swapped the relay as well).

I don't think the problem has been solved and it is probably only a matter of time before the fuse blows again..

any ideas?

 

Sounds like an electrical short somewhere. I would check out the fuel pump connections and make sure the assembly was mounted properly.

 

What have you done so far? The fuel guage and power all are in the same connector, obviously there is a short somewhere.

Take a meter and check it out. Or at least a good visual inspection. Often times corrosion is either the root cause or a major contributor to such a problem.

 

what has been done so far -
replaced fuse a few times (current one hasn't blown)
replaced fuel pump (because I have an extra - and it's a quick job)
replaced relay


by connector - you mean at the fuel pump?

 

I assume you made sure you had the correctly rated fuse.
Blowing a fuse is a sign of a failing pump motor. It's possible your known good one is also failing, but for now I'd look for a frayed wire that's periodically shorting out.

Whatever you do, don't put in a higher amp fuse.

 

Also, if the ground connection is unstable (broken or loose connection) such that it could suddenly lose contact then regain contact it would arc, it would momentarily lose power then suddenly make again, this could cause a problem similar to what you reported. Start at the top of the fuel pump with the electrical connector and work your way back inspecting the bundle with a flashlight and looking at as much of it as you can see. Or as was said, the fuel pump itself could be on the verge of failing and drawing more current. Also make sure the little strainer inside is clean. What about your fuel filter, is it fresh? If it is blocked, it may be part of the problem.

 

I had the same problem a couple of years ago. The short was in the O2 wires. These sensors take the 12 volts from the same relay and fuse that feeds the fuel pump. The wires of one of the oxygen sensors was in short with the block of the engine. I fould it very easy, and I solved it very easy with isolation tape.

Hope it helps.

 

That is an excellent nugget of knowledge to store away for future reference. Thanks for sharing your experience with us.

 

Well I have inspected every bit of wire that I can and still am blowing fuses.

I checked the O2 sensor wires.... No luck

Checked the connection at the fuel pump real well... No luck...

I am at a loss - any other ideas? Does anyone know where I can find a wiring diagram?

Thanks

 

Have you check in the full RAVE manual for the diagram?