Engine/Transmission (1994 - 1998) 95 2500 fuel return line replacement, any tips?

[ogravy]

My 95 is hard to start if the nose is pointing up hill and also when the tank goes below 1/2 it can be hard to start when level. So I'm looking at replacing the fuel return line. Any tips or suggestions would be helpful, I'll say thanks ahead of time.

 

[BigPapa]

Covered here back in '06.



https://www.turbodieselregister.com...-1994-1998/171159-any-tricks.html#post1633665



Scott

 

[mdhark3]

i dont know if that is actually your problem in could be in the sending unit in the tank the hard lines will sometimes get hole in them and you will have a hard time starting when the fuel is below the holes

 

[wcjp]

My 96' had dry rot in the supply/return. Bad gasket in the fuel pre heater assembly (also loose). The main culprit was the small performed hose from the fuel preheater to lift pump. I could see daylight through the hose. Dodge was 1 - 2 wks out for the hose. I replaced all with coast guard approved diesel hose from boat supply store. Ran a bigloop in the small performed line location. Now is a good time to upgrade the starter contacts to 24v. The starter usually has to come out for fuel line replacement.

 

[GAmes]

Don't limit yourself to the return line. Replace the supply line and the 90 degree bend hose from the prefilter to the pump (about $7 from Dodge). While you are doing that pull the fuel heater and toss it.

 

[MLee]

Don't limit yourself to the return line. Replace the supply line and the 90 degree bend hose from the prefilter to the pump (about $7 from Dodge). While you are doing that pull the fuel heater and toss it.

I pulled the heater last saturday, on mine, cleaned the screen, a 5/16 alan socket works great to remove the stud holding the heater in. That puppy was tight. When putting it back together make darn sure you tighten the bottom part when you reinstall it. It will suck air, and you will lose the prime, and you will have to re-prime, you will be frustrated.