Good evening,

 

I have a 1999 Dodge 24v and am looking at replacing the fuel return system.  Has anyone made their own return system? If so, do you have a list of parts used?  I may just buy stock parts, but would like other opinions.  I am looking at replacing the line at the back of the head, line from vp and the t fitting.  The return line going to the tank is in good condition and does not need replacing.  The other lines are rusting and starting to leak.  

 

Thanks,

 

Tim

The stock return lines more than adequate for the job, but i dont see why you could not put something together. Couldn't be that hard. I am going to something before pay the ridiculous price the tee grommets. 

 But to answer your question, i have not.

Stock setup is fine. No gains on oversizing. 

 

Return on the left and Supply on the right. Making a 1/2" return won't do any good. 

 

Thanks guys.  I priced all the parts using Cummins/Mopar part numbers and the price is over $250.  Was looking for ideas to make the system for cheaper but still be reliable and not leak.

 

Tim

DAP sells the OEM return lines for half of what Cummins wants. 

Edited December 31, 20186 yr by trreed

I would just replace the square cut o-ring. I would just give DAP a call I'm pretty sure he can get those. 

Thanks guys!  ill give DAP a call in the morning!

 

Tim

I just fixed the fuel leak on back of head. It’s not to hard. Just rove all wiring that is in the way and it is quite easy 

i just did the banjo washers....slowly reach in, find banjo and remove. the washers go right back on and tighten up.

 

i went to a cummins dealer, the washers were $2 a piece ( packaged in pairs, so $5) and the square cut inserts for the tee came out to like $15. they were the expensive part. i did not replace those yet, as when i tightened the banjo, the hard start nose up symptom stopped. 

56 minutes ago, Stormin08 said:

i just did the banjo washers....slowly reach in, find banjo and remove. the washers go right back on and tighten up.

 

i went to a cummins dealer, the washers were $2 a piece ( packaged in pairs, so $5) and the square cut inserts for the tee came out to like $15. they were the expensive part. i did not replace those yet, as when i tightened the banjo, the hard start nose up symptom stopped. 

You payed 15$ for all three grommets?

i did not purchase those, when this all started i tightened the banjo. problem stopped, for a short while then returned.

 

i did replace the banjo washers based on those actions...problem has not returned yet. the truck sat from 12-22-18 to 1-2-19, with the nose up after one restart of replacing the banjo washers. on 1-2-19 i cranked and it fired right up.