First time I've heard of the metal rail not having a test port. But if you can't stop the leak in the rig you made, there is no way to test the pump properly. Somehow I don't think that's the prob anyway. You need to check /test/clean the other stuff mentioned.

 

Here is a picture of the truck, not bad for free!http://i1083.photobucket.com/albums/...psbddfe135.jpg

Here is a video under the hood http://s1083.photobucket.com/user/be...07965.mp4.html

This on from inside http://s1083.photobucket.com/user/be...08623.mp4.html

Starting to think it might be the cat, just seems odd the this happened when it was parked

 

Remove the o2 to start with. I'm betting it's the problem(cat), but even if it isn't, you need to eliminate it as one.

 

OK, I pulled the O2 sensor, if it ran any better it is hard to tell. When first started it did rev better for a couple seconds (2 to 3) but with all the exhaust comming out of the O2 port couldn't hear anything else.
With the cat welded in how can I gut it out just to try. What are your thoughts on running gutted cat or no cat? Thanks again

 

the real question is - if it would not rev over 1200 rpm before, will it do so now? and rev up to 2000+ rpm?
if you're not sure, put the O2 back in and repeat the test....

if it does, replace the cat (or remove, or gut, or something).
if not, keep looking for the problem, and don't get sidetracked on an unnecessary cat replacement.

 

Over 1200RPM's only once when first started without O2 sensor, now it is worse. It will not idle now, drops to about 500RPM and then dies. Running out of daylight, hope to play with it more in the morning.

 

Was able to reinstall the O2 sensor before dark. After trying with and without O2 sensor I see no change in how the truck runs. Do you think the the cat may be so plugged that removing the O2 sensor does no reduce the backpressure enough to let the truck run better? May drop the exhaust at the manifolds and see if that helps. If you have any other ideas let me know.

 

Pressure check valve should be on the drivers side toward the back.... being it's a 96 with metal rail, it *should* be there. (capped, of course.)

Sounds like clogged cat.

 

i don't think so. the o2 hole should be enough to make a significant improvement. i think you have some other problem other than cat or fuel pressure.
maybe electrical. maybe a vac leak. maybe injectors.
how old is the gas?

 

After thinking about the problem overnight, I'm starting to think the problem could still be fuel pressure. At idle pressure is good but once demand for fuel goes up do you think the pressure could drop off (plugged filter). Once it gets daylight I am going to try my set-up again and see if I can stop the leaks. That way I could check fuel pressure at higher RPS and see how fast the pressure bleeds down.