I’m leaking fuel from a plastic line connected below and to the right of the fuel filter. I took out fuel filter but can only get one hand by the leak. I’ve tried getting at it from underneath and can’t. I took the wheel well plastic guard off and there is no room. My only option that I see is cutting the metal out of the wheel well big enough to get my hands at the problem. Would there be an access through the fire wall I don’t see. I think I put my fuel gauge in the wrong place because it aways maxes out at thirty and never goes lower. Besides the fuel leak I’m worried about my injector pump because my truck aways started right away and now I have to crank it multiple times pumping the petal to get it going. And that seems to me like no fuel. I think the plastic line that’s leaking might be a return to tank line. Could all the extra cranking to get it running harm my injector pump?

My 2002 has a plastic disconnect on the bottom of the tee on the return line. Mine was leaking, and I got new plastic inserts at NAPA. IIRC, they are 3/8.

Could you list the part numbers if you know them please. @greed

Unfortunately, I did not save the package. I checked my stash of inserts, and I believe it is a 5/16 insert. I checked the Dorman website and came up with Part# 800-005. Hope this helps.

Greed, are you saying you repaired the disconnect?

Well, that is part of it that is just the clip. 

Yes, I replaced the insert and the leak stopped.

That sounds like the easiest, the disconnect isn’t in a place to be able to disconnect it anyway. Is diesel fuel line different from regular fuel line. Piece of hose and two clamps sounds great compared to yesterday.

You just need hose that is compatible with diesel fuel. Some hose is not.

I was able to get to the disconnect from under the truck. IIRC, it was a pain, not much room, but doable.

It’s 34 degrees out and I have my 5 foot piece of hose and 2 clamps better now than never.

What about removing the Tee and relocate so its easier to get to? Using hose clamps, flexible fuel line and a brass barbed Tee, it seems  best to locate the Tee down low on the frame where it is easier to get to. Anyone see any problems with this mod?

29 minutes ago, James merritt said:

It’s 34 degrees out and I have my 5 foot piece of hose and 2 clamps better now than never.

 

Prayer the rubber hose never kinks. Sure hate to to see what pressure build up will do most likely blow the front seal of the VP44.

Huhh! My fuel line hose does not kink it is high pressure diesel fuel line hose. It expensive but cheap compared to what it is and how long the stuff lasts. It does not like to kink.

3 hours ago, Mopar1973Man said:

Prayer the rubber hose never kinks. Sure hate to to see what pressure build up will do most likely blow the front seal of the VP44.

 

2 hours ago, JAG1 said:

Huhh! My fuel line hose does not kink it is high pressure diesel fuel line hose. It expensive but cheap compared to what it is and how long the stuff lasts. It does not like to kink.

So @Mopar1973Man has kinky hose and @JAG1 does not. This sounds a bit strange.

Hahaha...there's so much that can be said here.  But since I'm the new guy I'd better zip it... ?

Edited October 13, 20186 yr by Bullet

All joking aside... why not move that problematic tee? There is no high pressure and my fuel returns dump into the fill necks on both trucks.  so no big deal right?

 

It is my estimation that tee is a poor location when it can be easily moved for servicing elsewhere. 

Edited October 13, 20186 yr by JAG1

36 minutes ago, JAG1 said:

All joking aside... why not move that problematic tee? There is no high pressure and my fuel returns dump into the fill necks on both trucks.  so no big deal right?

 

It is my estimation that tee is another rope you into the dealer kind of design when it can be easily moved for servicing elsewhere.

I dont see why you could not do it. Just do it in a professional manner. Me, I aint going back in there till she starts leaking again.

 

 

I see how you are when its not a chicken joke.

Edited October 13, 20186 yr by dripley

Wow,

all good stuff.

you just don’t know what you don’t know ! 

I read the move the T after I was done. And the T maintenance was for knot anyway, I spliced in a piece replacing the disconnect, and believe me I don’t have a clue why they call it quick. After 15 minutes no leak, better mileage here I come. Thanks everyone. It will be a day or two before my hands recover.

6 hours ago, dripley said:

 

So @Mopar1973Man has kinky hose and @JAG1 does not. This sounds a bit strange.

 

I was just pointing out a common issue I've seen. People like to use rubber hose for lots of things. Like when people attempt to do my crankcase mod with rubber heater hose the net result was some poor member stuck on the Al-Can Highway with the tappet cover gasket blown out and lost most of the engine oil. The only thing that stopped him was the Check Gage light and the Oil gauge being at Zero. 

 

So like the same thing happens with trying to get around that return tee in the back of the head. If you use rubber hose and for some reason, the return line should kink shut because of poor fitment then the front seal of the VP44 could be at risk. This is why I tend to suggest that the OEM return tee is kept and not modified.  

 

So have fun with your kinky theory...