FASS Fuel Filter Cross Reference: The Complete Guide to Finding the Right Replacement Filter for Your System

Finding the exact FASS fuel filter you need, especially when it's unavailable, can be stressful. Using a reliable FASS fuel filter cross reference is essential for matching your existing filter to compatible replacements from FASS themselves or other trusted brands like Donaldson, Baldwin, Fleetguard, WIX, and more, ensuring optimal engine protection and performance.

Maintaining a clean fuel supply is non-negotiable for the health and longevity of any diesel engine. FASS Fuel Systems are widely respected for their high-performance lift pumps and integrated filtration solutions, designed to provide superior fuel cleanliness and protection for demanding applications. At the heart of this protection is the fuel filter. But what happens when your scheduled maintenance arrives, or you face an unexpected clog, and the specific FASS filter you need isn't on the shelf? This is where understanding and utilizing a comprehensive FASS fuel filter cross reference becomes crucial. It empowers you to identify the correct alternative filter quickly, preventing downtime and ensuring continued engine protection.

Understanding FASS Fuel Filter Identification

The first step in successful cross-referencing is correctly identifying your current FASS filter. FASS utilizes specific part numbers printed directly on the filter housing or canister. These numbers typically follow patterns that indicate the filter type and its specific application. Common FASS fuel filter part number prefixes include:

  • FPS Series (Fuel Pump System Filters): Examples include FPS0039P, FPS0105P, FPS0253P. These are often spin-on style filters specific to FASS lift pump systems.
  • DF Series (Dual Filter System Filters): Examples include DF100, DF165, DF300. These typically indicate filters designed for FASS's dual filter setups.
  • Other Designations: FASS also produces filters designated like FF5509 or for specific systems like Titanium Signature Series (e.g., TSPC7001A). Newer models might use series names like XP, HD, Platinum, etc., combined with specific part numbers.

Always locate and record the full part number from your existing filter before attempting to cross-reference. Taking a clear photo of the label and filter model markings is also highly recommended. Misidentification is the most common cause of failed cross-referencing attempts.

Why Accurate Cross-Referencing is Critical

Simply grabbing any filter that "looks about right" or has a similar-sounding number is a recipe for problems. Diesel fuel filters must meet very specific engineering requirements to function correctly within a fuel system:

  1. Micron Rating: This critical specification defines the size of the smallest particles the filter is designed to trap. FASS filters often feature multi-stage filtration with different micron ratings for primary and secondary elements (e.g., 30 microns primary, 3 microns final). Using a filter with the wrong micron rating can mean inadequate protection (too large) or excessive restriction and premature plugging (too small).
  2. Flow Rate: The filter must be able to pass the volume of fuel demanded by the engine at peak performance levels. An under-sized filter creates excessive restriction, potentially causing fuel starvation, cavitation (damaging bubbles forming in the fuel), power loss, and accelerated wear on the lift pump.
  3. Burst Pressure Rating: Fuel systems operate under significant pressure. A filter not rated for the pressures generated by your specific FASS lift pump and engine system can rupture, causing a catastrophic fuel leak and fire hazard.
  4. Thread Size and Pitch: This determines if the filter physically screws onto the mounting head correctly. An incorrect thread pattern will prevent installation.
  5. Sealing Surface Design: The gasket(s) must match the sealing surface(s) of the filter head perfectly to prevent leaks under pressure. The wrong gasket design or material can lead to seepage or outright failure.
  6. Height and Outer Diameter: Physical dimensions matter for fitment within the allocated space under the hood. An oversized filter might not fit, while an undersized one might lack adequate dirt-holding capacity.
  7. Compatibility with Fuel Additives: Filters must be compatible with any additives (e.g., cetane boosters, lubricity enhancers, anti-gel) commonly used in the fuel. Some materials degrade with certain chemicals.
  8. API, ISO, and OEM Standards: Meeting relevant industry standards ensures baseline performance and compatibility expectations are met.

An accurate cross-reference ensures the replacement filter matches these specifications as closely as possible, preserving the intended performance and protection level of your FASS system.

Sources for Reliable FASS Fuel Filter Cross References

Finding trustworthy cross-reference information is key. Avoid relying solely on anecdotal suggestions. Instead, consult these authoritative sources:

  1. The FASS Website and Catalog: Always the best starting point. FASS provides detailed parts catalogs on their website, often listing their own supersessions (when an older part number is replaced by a newer one) and sometimes direct cross-references to major competitive brands. Search using your exact FASS part number.
  2. Major Filter Manufacturer Websites: Leading filter brands like Donaldson, Baldwin (Parker), Fleetguard (Cummins), WIX/NAPA Gold, Luber-finer, and Hastings maintain extensive, searchable online cross-reference databases.
    • Enter the known FASS part number into the competitor's cross-reference tool.
    • These databases are generally reliable but always cross-verify against filter specs if possible.
  3. Reputable Aftermarket Parts Suppliers: Established suppliers like Diesel Filters Online, Pure Diesel Power, XDP (Xtreme Diesel Performance), and others specializing in diesel performance and filtration often publish detailed cross-reference charts specific to popular FASS systems. They frequently have direct access to manufacturer cross data.
  4. Professional Service Manuals and Technical Bulletins: OEM (Original Equipment Manufacturer, e.g., Ford, GM, Ram, John Deere) service documentation and technical service bulletins sometimes include filter specifications and cross-reference information for aftermarket systems like FASS when applicable. Information from the pump/engine manufacturer is valuable.
  5. Direct Measurement & Verification: When in doubt, or if online data conflicts, physically comparing the specifications of your old filter to a potential replacement is essential. If the old filter is intact:
    • Measure: Micron rating (usually on label), overall height, outer diameter, thread size (you may need thread gauges), gasket dimensions.
    • Compare Labels: Look for flow rate, burst pressure, and API/ISO standards listings on both the old and new filter packaging or labels.
    • Inspect Sealing Surfaces: Visually compare the gasket type, location, and design.

Common FASS Filter Models and Corresponding Cross-References (Always Verify!)

While direct cross-references change over time as manufacturers update parts, the following table provides examples of common FASS filters and their frequent equivalents from major brands. THIS LIST IS ILLUSTRATIVE ONLY. ALWAYS CONFIRM THE MATCH USING THE SPECIFIC PART NUMBER AND SOURCES OUTLINED ABOVE, ESPECIALLY FOR YOUR ENGINE AND FASS SYSTEM MODEL.

  • FPS0022P / FPS0022P-CV (Common on 95-02 Dodge 5.9L Cummins with FASS)
    • Donaldson: P502007, P502013
    • Baldwin: BF983
    • Fleetguard: FF5490
    • WIX: 33339
    • Luber-finer: LFF3590
  • FPS0039P / FPS0039P-CV (Common on GM Duramax LB7/LLY/LBZ)
    • Donaldson: P502024
    • Baldwin: BF985
    • Fleetguard: FF5509
    • WIX: 33737
    • Luber-finer: LFF3619
  • FPS0105P (Common on 03-07 Dodge 5.9L Cummins, Ford Powerstroke 6.0L/6.4L)
    • Donaldson: P550509
    • Baldwin: BF7851
    • Fleetguard: FF5509
    • WIX: 33737 (Note: Same as FPS0039P - double check system specifics!)
    • Luber-finer: LFF3619
  • FPS0253P (Common on 2006-2010 Dodge 6.7L Cummins with FASS)
    • Donaldson: P502118
    • Baldwin: BF7841
    • Fleetguard: FF5526
    • WIX: 33727
    • Luber-finer: LFF3615
  • DF100 / DF100-2 (Series, often Primary Filter in Dual Systems)
    • Donaldson: P550590 (often corresponds to micron rating)
    • Baldwin: BF7990 (often corresponds to micron rating)
    • Fleetguard: FS5071 (30 Micron), FS5072 (10 Micron) - Must Match Micron Rating
  • DF165 / DF165-2 (Series, often Final Filter in Dual Systems)
    • Donaldson: P550599 (often corresponds to micron rating)
    • Baldwin: BF7999 (often corresponds to micron rating)
    • Fleetguard: FS5073 (5 Micron), FS5074 (3 Micron), FS5075 (2 Micron) - Must Match Micron Rating
  • FF5509 (Specific Model)
    • Donaldson: P502024, P550509
    • Baldwin: BF7851
    • Fleetguard: FF5509
    • WIX: 33737
    • Luber-finer: LFF3619
  • TSPC7001A (Titanium Signature Series Main Filter)
    • Donaldson: P551267 (Likely, verify micron rating/flow)
    • Baldwin: BF7810 (Likely, verify micron rating/flow)
    • Fleetguard: FS56286 / FF612 (Likely, verify micron rating/flow)
    • Important: Titanium Signature Series often require precise matches; consult FASS or supplier.
  • XP Series / HD Series / Platinum Series Filters: FASS uses distinct part numbers for filters specific to these performance lines (e.g., XP0105P, HD0039P-CV, PLT253P). Cross-reference must be done using the exact part number and considering the higher flow requirements of these systems. Higher micron-rated primaries are common in performance systems to support high flow without restriction.

Important Cross-Referencing Considerations

  1. "Close" is Not Good Enough: A filter that "almost" fits or has a "similar" number is inadequate. Differences in micron ratings, flow rates, or sealing surfaces can have significant negative consequences. Never assume compatibility based solely on visual similarity or conjecture.
  2. Primary vs. Final Filters: In multi-stage FASS systems (like the Dual Filter or Titanium Signature setups), pay strict attention to which filter (primary or final) you are replacing. Primary filters generally have higher micron ratings (e.g., 30, 50, 100 micron) to capture larger contaminants and protect the finer final filter. Final filters (e.g., 2, 3, 5 micron) provide the final layer of protection for injectors. Confusing them compromises system performance and protection.
  3. Check Both "Replaces" and "Replaced By": Part numbers get updated. Your FPS0039P might have been superseded by FPS0039P-CV. Competitors' cross-reference lists should show both what a competitor filter replaces and if that competitor filter has been superseded itself. Ensure you are looking at the current, active part number.
  4. Beware of Outdated Cross Lists: Online forums or older printed material might contain cross-references that are no longer accurate due to part supersessions or changes in filter specifications. Always prioritize information from the filter manufacturers' current websites or authorized dealers.
  5. Verify Packaging Claims: When purchasing, ensure the filter packaging clearly states the specifications and cross-references. If the specs don't align with your requirements or the cross-reference label seems generic, it's a red flag.
  6. Fuel Type Compatibility: Ensure the filter is rated for the type of fuel used – standard diesel, ultra-low sulfur diesel (ULSD), or biodiesel blends (B20, B100). Compatibility may vary.

Consequences of Using an Incorrect FASS Filter Replacement

The risks of using the wrong filter range from inconvenient to severely damaging:

  1. Poor Filtration: Using a filter with too large a micron rating allows harmful particles into the injectors, causing wear, scoring, and potential failure. Injector replacement is extremely costly.
  2. Fuel Flow Restriction: A filter not rated for the required flow, or one that plugs prematurely due to incorrect micron sizing or inadequate capacity, starves the engine of fuel. This causes power loss, hesitation, hard starting, stalling, and potential lift pump damage from excessive workload.
  3. Leaks: Incorrect thread size, pitch, or gasket design/seal material leads to fuel leaks. This is a significant fire and safety hazard, wastes fuel, and draws in air causing further running issues.
  4. Filter Collapse or Rupture: Exceeding the filter's burst pressure rating (common if using a filter not rated for a high-performance FASS pump) can cause the filter canister to collapse internally or rupture. This sends debris throughout the fuel system and causes immediate fuel loss.
  5. Warranty Implications: Installing a non-specification filter could potentially void warranties on both the FASS system and the engine it protects, especially if failure can be traced back to poor filtration.
  6. System Overheating: Excessive fuel restriction generates heat within the fuel system, which can degrade fuel and components.
  7. Increased Operating Costs: Injector damage, lift pump failure, downtime, and wasted fuel from leaks all contribute to significantly higher operating costs compared to using the correct, affordable filter from the start.

Steps to Safely Perform a FASS Filter Cross Reference

  1. Identify: Locate the exact FASS part number on your old filter (and its micron rating if visible). Note the FASS system model if known.
  2. Consult FASS First: Check FASS's official website/catalog for their current replacement part number, supersession information, and any published cross-references.
  3. Check Competitor Databases: Enter the FASS part number into the online cross-reference tools of at least two major competitors (e.g., Donaldson and Fleetguard).
  4. Verify Key Specs: Compare the critical specifications of the suggested competitor filters:
    • Micron Rating(s): Primary/Secondary/Final
    • Flow Rate (GPH or LPH)
    • Thread Size and Type
    • Gasket Design/Seal Count
    • Burst Pressure Rating
    • Physical Dimensions (if space is tight)
    • API/ISO Standards
  5. Check Application Guides: Some competitor websites allow searching by vehicle application. If this matches your vehicle and the proposed filter specs also align with the FASS filter specs, it adds confidence.
  6. Consult Trusted Suppliers: Contact a reputable diesel performance or filtration specialist supplier. Provide them with the full FASS part number and your system/vehicle details. Request their verified cross-reference options. Compare their suggestions with your research.
  7. Purchase and Inspect: Once purchased, before installation, inspect the new filter packaging and label. Ensure it lists the exact competitor part number you intended to buy and that key specs match expectations.
  8. Physical Verification (If Possible): If you have the old filter, physically compare the sealing surfaces, gasket type, thread engagement, and dimensions if you have doubts or face conflicting information. Measure micron ratings cannot be verified visually; rely on labeled specs or brand reputation.
  9. Install and Monitor: Install the filter correctly, ensuring seals are lubricated with clean diesel or compatible oil, and torqued to specification (if provided). Prime the system (if necessary) and monitor for leaks, pressure fluctuations (if your system has a gauge), and engine performance after installation. Pay attention during the next few operating cycles.

Specific Considerations for Advanced FASS Systems

  • Dual Filter Systems (DF Series): Meticulous separation of primary and final filters is paramount. Primary filters typically have higher micron ratings (e.g., DF100 series) and final filters have fine ratings (e.g., DF165 series). Cross-referencing must maintain the stage-specific micron rating and flow rate. Mixing up stages or using incorrect micron levels disrupts the designed filtration efficiency and protection levels.
  • Titanium Signature Series (TSPC): These are high-flow systems demanding filters capable of handling significant flow rates without restriction. While cross-references exist, the flow rating matching is even more critical here than on standard systems. Using a standard filter not rated for the flow can cause immediate restriction and damage potential. Prioritize FASS recommendations or high-flow specific equivalents from major manufacturers verified for this flow rate level.
  • XP, HD, Platinum Series: Similar to Titanium, these performance systems are designed for high horsepower applications. Filters like XP0105P or PLT253P need to accommodate high flow. Cross-references should come from sources knowledgeable about high-performance diesel applications, confirming the alternative filter meets the increased flow demand. Filters like a Baldwin BF7886 are often specifically mentioned for high-flow FASS systems, but always check the exact part number.

The Importance of Buying Quality Replacement Filters

Once you've found the correct cross-reference part, purchase filters from authorized dealers or reputable distributors. Counterfeit or extremely cheap, off-brand filters can pose significant risks:

  • Questionable Materials: Using inferior media, seals, or metal components.
  • Inaccurate Specifications: Misstated micron ratings or burst pressures.
  • Poor Construction: Potential for leaks, collapse, or bypass.
  • Inconsistent Performance: Failure to meet even basic filtration standards.

Stick with recognized brands like FASS, Donaldson, Fleetguard, Baldwin, WIX/NAPA Gold, Luber-finer, or Hastings. Their reputation hinges on meeting engineering specifications and quality control standards. While the initial cost might be slightly higher than an unknown brand, the protection for your expensive diesel engine and injection system makes it a wise investment.

Conclusion: Knowledge is Power and Protection

Dealing with fuel filter replacement doesn't have to be a headache or a risk. Mastering the use of a reliable FASS fuel filter cross reference empowers you as a diesel owner or technician. By meticulously identifying your current FASS filter, consulting authoritative sources from FASS and major competitors, rigorously verifying critical specifications, and purchasing quality replacements, you ensure seamless maintenance without compromise. This diligence guarantees your FASS system continues to deliver clean fuel, protecting your engine's injectors, pump, and overall performance for the long haul. Never settle for guesswork when it comes to your diesel's lifeline. Accurate cross-referencing is a fundamental step in responsible diesel engine maintenance. Keep your reference sources bookmarked and always double-check specs – your engine will thank you.

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