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Duramax Fuel filter head rebuild

Discussion in 'Fuel, Air, & Exhaust Upgrade DIY' started by blksmok, Oct 11, 2010.

  1. blksmok

    blksmok Administrator Staff Member Shareholder

    Tools needed:
    Filter head rebuild kit
    #20 Torx bit
    Large flat head screwdriver
    Small flat head screwdriver
    Ratchet with extensions and 1/2" socket (for battery removal)
    5/16" wrench (for battery removal)
    12mm wrench for filter head removal

    [​IMG]

    Step 1.
    Remove the filter head using the 12mm wrench.

    [​IMG]

    I like to remove the battery to gain more room and better access.

    [​IMG]


    Step 2.
    Remove the 3 #20 torx screws

    [​IMG]


    Step 3.
    Using the o-rings from the kit in largest to smallest order:

    [​IMG]

    Replace the largest o-ring here:

    [​IMG]


    Step 4.
    On the under side, remove the 2 #20 torx screws.

    [​IMG]

    Then replace next largest o-ring here:

    [​IMG]


    Step 5.
    Replace the next largest o-ring here:

    [​IMG]


    Step 6.
    And finally, the smallest o-ring here:

    [​IMG]


    For the standard kit, put everything back together and you're done. :thumb:

    If you bought the deluxe kit that includes the plunger seals, you have two more steps.
    The plunger seals are under the metal plunger cap.

    [​IMG]

    Remove the old seals and replace with the new seals from the Deluxe kit.
    Note the orientation of the edges of the seals. The top seal edge should be at the top and bottom seal edge at the bottom.

    [​IMG]

    Put everything back together and you're done. :thumb:
    Last edited: Aug 3, 2013
  2. KEVINL

    KEVINL New Member

    Thanks Dave

    I have one at home that needs rebuilt

    where did you get the oring kit the dealer?
  3. blksmok

    blksmok Administrator Staff Member Shareholder

    No, the dealer will only sell you a new head (for $400 - $750) with the same poor quality o-rings that dry out, crack and leak air from ULSD and swell and leak air from bioD.

    I had to source my own parts because none of the aftermarket kits gave me enough information to know if they were the viton that is suitable for 100% bioDiesel. (there are several viton specs, and not all are great with bioD)

    Anyway, I sourced my own kit with Viton type A O-rings that are great for bioD and even better with pump diesel. I bought in bulk and will be able to offer the kits for only $11 with shipping. That's half the cost of the cheapest I found it online anywhere. :thumb:
  4. Chris Tobin

    Chris Tobin Freelance Editor

    Sounds like a simple but very worthwile upgrade... I guess I'll have to do this on my LB7 project and shoot/write it up for a magazine article...
  5. MMAoflapjack

    MMAoflapjack New Member

    Yeah I got your kit bout a week ago, saved me $750.00, that's what the dealer wanted for the new head here in Texas. Very easy to do and well worth it to get the pump gaskets at the same time. Thanks very much.:Handshake::thumb:
  6. blksmok

    blksmok Administrator Staff Member Shareholder

    :welcome:

    Glad to help. :thumb:
  7. Redtruck

    Redtruck New Member

    My 02 was/is for sale when this problem happened. (how embarassing) This had already happened to a friend and I saw what he paid for the housing at the dealer. A google search led me to here. I decided a 16 dollar gamble was in order. When kit arrived, I started to try and remove the housing but just too much stuff was in the way pissin me off. With the help of a small mirror and a friend holding the light and being very very carefull I managed to put the kit in without removing the housing. Worked like charm! Truck starts and stays running. Thanks for the very good deal!! and write up with pictures. Would not have even tried without that
    Last edited: Jun 26, 2011
  8. blksmok

    blksmok Administrator Staff Member Shareholder

    :welcome:

    And thanks for the feedback. Glad to help. :thumb:
  9. madmaxdmax

    madmaxdmax Sand Dune Fanatic

    Dave...how many more of these kits do you have available ?


    BTW...We will have to meet up somewhere so I can get one from ya if you still have some:secret:
    Last edited: Jun 29, 2011
  10. blksmok

    blksmok Administrator Staff Member Shareholder

    All Kits are in stock.
  11. stugotz

    stugotz New Member

    wow, blksmoke thanks so much, I finally had the time to put in enough hours today to remove, rebuild, re-install my filter housing, using your wonderful rebuild kit, and she runs like a champ.

    i have a 2003 duramax 2500 4x4.

    What i especially love is getting over on the outrageous dealer price and labor quote to have it repaired at the dealer.

    thumbs up to you my friend.

    I am not to far from you, as I live in San Tan Valley
    Last edited: Jul 11, 2011
  12. blksmok

    blksmok Administrator Staff Member Shareholder

    Glad to help. :thumb:

    :welcome:
  13. Is there a # that the screws should be torqued to? Or just snug?
  14. blksmok

    blksmok Administrator Staff Member Shareholder

    I just tightened them down about as tight as I found them. Not sure about a torque spec...
  15. Ok thanks. And thanks again for the kit. No problems with my original one yet. But I have a fresh one ready to go for when it decides to take a dive.:thumb:
  16. crazypup

    crazypup New Member

    Hi, I would like to place an order today if you still have some left
  17. blksmok

    blksmok Administrator Staff Member Shareholder

    Sure do.
    Use the first post in this thread to place your order.

    Thanks,
  18. glbrt2500

    glbrt2500 New Member

    Still have any kits?
  19. blksmok

    blksmok Administrator Staff Member Shareholder

    Sure do.
    Use the first post in this thread to place your order.

    Thanks,
  20. billd

    billd New Member

    2008 duramax

    whats up everyone i am new to this and just wanted to say i ordered the o ring kit from blksmok it shipped right away and totaly cured the problem that the dealer and others had cost us over 1200.00 dollars and still not fixed problem. so just wanted to say blksmok awesome post.. great pics and excellant oring kit keep it up you have a fan right here.

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