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  • Problems with Caterpillar fuel/water seperator

    I have just bought a new cat 144-9962 fuel/water separator.
    This assmbley has the 156-1200, 5 micron filter fitted to the housing and glass bowl.

    I wanted to fit a 30 micron or 150 micron filter, so fuel flow wouldnt be restricted too much.
    So I ordered a 100-6374 filter which is 30 micron, but this has been superseded to 138-3100, which is part number for a 150 micron filter.

    When I got home I decided to remove the 5 micron filter, and fit the 138-3100 which is either a 150 or 30 micron filter.
    The problem is that the locating lugs on the filters are not the same. See photos below.
    So the filter will not locate into the housing, to enable the filter to be pushed up.
    So there must be another filter housing for the 138-3100 filters!
    Can anyone help?

    Or have I just got 2 dodgy 138-3100 filters?

    [IMG][/IMG]

    [IMG][/IMG]
    Last edited by GXL14; 08-05-2014, 09:39 AM.
    Prado Dec 2013 GXL
    Turbo diesel, Automatic trans

  • #2
    G'day mate,
    Yep housings are different I did the exact same thing!. I was lucky I know the local cat parts man well (use cat through work, earthmoving) and was able to swap housings over. Another thing you can try is Donaldson or fleetguard filters on the housing you have now as they might make a 30 or higher micron filter that suits.
    Cheers.
    2016 1GD GXL 6 speed auto, ARB colour coded summit bar, LED driving lights, duel batteries, BF Goodrich tyres, window tint.

    Comment


    • #3
      I have done a bit of research and it looks like the 138-3097 filter group is compatible with the 138-3100/100-6374, 30/150 micron filters.
      Can anyone confirm this?
      Prado Dec 2013 GXL
      Turbo diesel, Automatic trans

      Comment


      • #4
        Went to cat dealer this morning and checked out the info on their SIS (service information system).
        The 138-3097 filter group includes the 100-6374, 150 micron filter.
        Also the 138-3097 150 micron filter group, is twice the price of the of the 5 micron 144-9962 filter group!
        You also can't just buy the filter housing head. But can buy the glass bowl, seals and bleeder caps separately.

        So if you want a 30 or 150 micron fuel/water separator unit, it would as cheap to get the fuel manager kits.
        Then buy the Cat 100-6374 filter when needed, as they cheaper than the fuel manager 150 micron filters.
        But if you want a 30 micron filter it looks like you only have the option of the fuel manager filter.
        Last edited by GXL14; 08-05-2014, 03:10 PM.
        Prado Dec 2013 GXL
        Turbo diesel, Automatic trans

        Comment


        • #5
          Photos of 138-3097 Filter group after being fitted to my 150 series.

          [IMG][/IMG]

          [IMG][/IMG]
          Prado Dec 2013 GXL
          Turbo diesel, Automatic trans

          Comment


          • #6
            If you want more clearance underneath, remove the bowl and just use the drain plug direct in to the filter. If you drain the filters every 5000km, the bowl doesn't serve much purpose as you can't see if there's water in there anyway without unbolting the filter.
            2019 GXL, Bullbar, UHF, Redarc Brake Controller, Tow Bar, Secondary Fuel Filter

            Comment


            • #7
              How much are the complete housing and filters?
              150 Prado D4D GXL Blue Storm, T13 TJM Bar, 265/70/17 Goodyear MTR Kevlar, Tigers11 1200 pound 2 speed Winch, Fox Shocks remote resevor, Air tec Snorkel, ARB Air Lockers Front and Back, Off Road Systems Draws with Drop Down Fridge Slide, Wetsuit seatcovers.

              Comment


              • #8
                144-9962 $86.32 - complete housing, with 5 micron filter and glass bowl
                138-3097 $167.12 - complete housing, with 150 micron filter and glass bowl.
                138-3100 $25.61 -150 micron filter element.

                Cant believe the 150 micron group was twice the price of the 5 micron group!
                They look identical to each other. Only the slots for the filter lugs are in different positions.
                Prado Dec 2013 GXL
                Turbo diesel, Automatic trans

                Comment


                • #9
                  Bumping an old thread. Price for 9962 is close to 100 now. Anyway was looking at the specs for Toyota factory replacement filter and that is 10 micron. Now I am sure there are many that have said the Toyota filter is 2 micron. I am about to install a 5 micron Cat 144-9962. So if Toyota is 10 micron then is it a good idea to have a finer filter before it. Will that cause issues for the injection system? If Toyota is 2 micron then 5 micron should be fine. Let's start the discussion again
                  D4D. How long will it last?

                  Comment


                  • #10
                    What is a Fuel System Transfer Filter. The service manual says it must be changed every 20k for D4D? Is the as the under bonnet fuel filter?
                    D4D. How long will it last?

                    Comment


                    • #11
                      Originally posted by wanted View Post
                      What is a Fuel System Transfer Filter. The service manual says it must be changed every 20k for D4D? Is the as the under bonnet fuel filter?
                      The transfer filter is underneath between the two tanks. It is different to under the bonnet

                      Comment


                      • #12
                        Originally posted by Rdae1981 View Post
                        The transfer filter is underneath between the two tanks. It is different to under the bonnet
                        Thanks for the information. It must be doing a poor job in most cases as people are installing pre filter on their Prado's. Do you know (apart from obvious filtering ) what that filter is meant to do? What is the magical Micron number for it?

                        So that makes perfect sense when people do not find any mention of under bonnet filter change schedule in the service book!
                        D4D. How long will it last?

                        Comment


                        • #13
                          Originally posted by wanted View Post
                          Thanks for the information. It must be doing a poor job in most cases as people are installing pre filter on their Prado's. Do you know (apart from obvious filtering ) what that filter is meant to do? What is the magical Micron number for it?

                          So that makes perfect sense when people do not find any mention of under bonnet filter change schedule in the service book!
                          Sorry wanted thats about where my knowledge stops lol I do know that the transfer filter gets changed out every 20,000kms and the under bonnet is only as required I think the main reason for a second under bonnet filter is purely for peace of mind.

                          Comment


                          • #14
                            Does anyone know what the fuel flow specification for 144-9962 is? Most product websites have the flow rate mentioned except Caterpillar. Being a US product I expect it be in Gallons per hour or Gallons per minute. Cannot find that information anywhere. Anyone member work for Cat who can help with the information. Going by some of the engines this products work for include a 3.3 ltr motor and one 4.0 ltr motor, other are lower volume (cc) engines. So I am seeking this information before fitting the unit. I hope it will make some facts come to light.
                            D4D. How long will it last?

                            Comment


                            • #15
                              the filter under the bonnet is to stop the big contaminate from getting into the injectors and causing engine failure, and most importantly keeping water out as well.

                              http://www.direction-plus.com/produc...on-components/

                              Comment

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