Jim, try adding a sump or going with a bigger suction line, the pump just might be working too hard to pull the fuel up out of the tank.

I've been told they basically are running at max capacity all the time...

If it was me, I'd put a sump in and call it a day. You may need larger fuel line from tank to pump too. I know guys with the A1000's and Fuelabs are using 5/8 line, anything smaller is starving those pumps. I'd ask the guys at AD what they recommend, or look in the owners manual if it came with one.

 

I re-read through this thread and it seemed to me that all energy was focused on fluid flow and very little on electricity. Here's what I suggest in 2 parts:

Call Air Dog and ask how they recommend it be plumbed on a 6.0. Ask if a lift pump is needed like in an AD150 system (the frame mounted pump could work for testing purposes in that case). If a lift pump is needed and not used, this could be why you are burning up these motors. By the same token, if a lift pump isn't needed and you are still using your frame mounted pump, the two could be fighting each other.

Next, if it is all plumbed as recommended, re-check EVERY WIRE. If I were changing electrical components at the rate that you are, I would check how I wired it in. This point seems to be brushed aside with every new post.

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Here are somethings that I have picked up reading other sites about the AD2:
1. It has a high failure rate and is taking a beating because of it.
2. It doesn't use a lift pump (it pushes fuel to the regulator or the heads)
3. One user made another wiring harness using 10 gauge wire (pretty big) and was kicking around using a lift pump with it. This user had also gone through 3 pumps.
4. I believe that it works best with a sump like Mike already suggested.
5. Their customer service doesn't have a very good reputation.

Sorry, Jim, I don't think this is what you were hoping to hear, but that's what I found. Personally, I like #3 the best.

 

I keep asking what is the problem in Customer Service!!!!

now i was told by Kyle ( customer Service) they came out with a new pump since August

The pump is different and bolts up to the existing kit

What pressure should i run?? i was thinking the minimum because there is a regulator in the fuel bowl....

When i get back to dry land ....i plan to pull out the feed lines and put a T and use the new banjo bolts and adapters to the heads...

Then cap of the return line from pump like in the previous schematic

i have spent 900 in hotel and 160 tow bill ...plus beer and hard whiskey...waiting for the pump to come.....

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Do i drop the tank and cut a hole in bottom for the sump pump.....what pump should i use....

I followed the manual during installation....

it seems i am blowing the pump every 10,000 miles like clock work

 

Not a sump pump, just a sump. You cut a hole in the bottom of the tank and bolt the sump in, it just lets your current AD2 pump pull fuel from the bottom of the tank, instead of having to pull it from the bottom to the top and then to the pump, it's just making it work harder that way. This way it's almost gravity fed to the pump, so it can do more pushing and less pulling. (pumps prefer to push instead of pull).

Sump:

 

^^^ It's not anodized red....

But seriously, I read about needing some sort of reducer like this one:

Aeromotive | 16306 - Billet Fuel Pump Speed Controller

to better match the speed of the pump to the engine WITHOUT reducing voltage. This may be what the AD2 needs.

Either way, I'd try plumbimg that AD2 to my frame mounted pump and see what that does. This is how the AD 100/150s are run with a good deal of success.

 

The AD2 is made to completely replace the AD150's/100's. It's a stand alone high pressure unit, the AD150's are low pressure...

 

Alrighty then, belay my last about using the frame pump (HFCM I think), but I still wonder if that part I linked, or something like it, wouldn't relieve the load on the AD2 pump. Further research has also confirmed that a sump helps, too.

 

just a note
i got 18 mpg on the truck after the fuel pump set at 30 psi
before had set at 40 psi got 16 mpg

plus they told me new pump design after august

 

Keep you all updated on the latest news about AD2.

http://www.powerstroke.org/forum/6-0...2-carnage.html

http://www.powerstroke.org/forum/6-0...ease-read.html

 

Thanks for the update! Glad to hear that!