Engine/Transmission (1998.5 - 2002) Anyone ever had a cracked Banjo Fitting?? Help

[SLightfoot]

Well, about 2000 miles after installing my new VP44, I started experiencing the "hard start" condition.



Yep, I was worried, until I started doing some troubleshooting, and found the tell-tale fuel seepage from the Fuel Return line on the VP44. Turns out there is a fine hairline crack where the return line goes into the banjo fitting. Hard to tell if it's the line itself of the brazing that's cracked. After some manipulation of the line, the fuel is spraying out (leaking) at a fairly high (and dangerous) rate. It's definately not the gaskets, as I've pulled the whole return line off, and can blow air through and feel the air leaking out of the crack.



Has anyone ever had this happen before?



If so, can it be repaired, or do you have to buy a new line.



Surely this must have happened to someone here... . looking for a little "been there, done that" advice.



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Thanks,



Shawn

 

[SMoryski]

Hello neighbor

Yes I also have had a soldered banjo connection crack, only it was on my supply line at the VP44. You can clean the fitting and have it brazed, oxyacetylene, using a brass filler rod. any welding shop should be able to braze this up for you in a matter of minutes.

 

[SLightfoot]

Well howdy!!



Thanks for the info... upon closer inspection today, (I took emery cloth to the area and cleaned it right up) - I see that the tube itself is hairline cracked.



Do you think that the cracked tube itself can be braze-repaired?



Thanks,



Shawn

 

[Bob4x4]

It can be TIGed but if you don't have one it would be cheaper to buy the line





Bob

 

[SMoryski]

I don't know what the cost would be for the fuel return line, but I do know that the short supply banjo fitting on the VP44 was about $130. 00 CDN. As you already know the fuel return line is alot bigger and would probably cost alot more than having it Brazed or Tig welded, just a guess. As for brazing this fitting, it will hold. My supply line was actually cracked the same as your return line. I was able to braze it myself. In an emergency I have had to braze cracked & worn thru steel hydraulic lines at harvest on combines, as my Dad was to cheap to buy new lines, These hydraulic lines are still holding strong 10 years later. Of course we would all like to repalce worn components with new ones, but this will get you by in a pinch.

 

[SLightfoot]

Well, it's fixed now... .



I went into Cummins this morning and picked up a new fuel return line.

Turns out, the cost wasn't that bad really - $71 CDN. I was quite surprised.



Since the entire length is all rigid line, and secured at the block halfway, the slightest bit of vibration is going to exaggerate the tiniest amount of load that is on those fittings, and eventually crack them again.



Anyway, I decided that this is clearly yet another design weakness in the fuel system, so now that I'm at least up and running, I'm going to modify the old one that I took off.



I'm going to first of all get the cracked end braze-repaired. Then I will cut out a 4" section of the rigid line and insert a rubber fuel hose to act as vibration and torque relief on the banjo fitting. I noticed that Cummins did this on the INPUT line to the IP, but not the return line, which in my quick assessment is at higher risk for cracking.



Well, at least it's running again. . but man am I sick of pouring money into this thing lately... ...



Cheers,



Shawn

 

[gtobey]

Well, about 2000 miles after installing my new VP44, I started experiencing the "hard start" condition.



Yep, I was worried, until I started doing some troubleshooting, and found the tell-tale fuel seepage from the Fuel Return line on the VP44. Turns out there is a fine hairline crack where the return line goes into the banjo fitting. Hard to tell if it's the line itself of the brazing that's cracked. After some manipulation of the line, the fuel is spraying out (leaking) at a fairly high (and dangerous) rate. It's definately not the gaskets, as I've pulled the whole return line off, and can blow air through and feel the air leaking out of the crack.



Has anyone ever had this happen before?



If so, can it be repaired, or do you have to buy a new line.



Surely this must have happened to someone here... . looking for a little "been there, done that" advice.



#ad




Thanks,



Shawn

If anyone has this problem again, I do silver soldering, and will try to help you with repairing them much cheaper than buying a new one. That is, if you can send it to me in Salem, VA and wait to get it back. Otherwise, check locally with your hydraulic hose and fitting specialists and see if they do silver soldering. That might save you some $$$. Take care...