2nd Gen Non-Engine/Transmission Aux line on fuel module surprise!

[Nate]

Went to hookup a fuel line to the stock tank for my aux tank and had a bit of a surprise.



I was told it was 3/8". Not the case at all... it's 5/16"! Guess I need to put a 3/8" to 5/16" adapter or just run all 5/16" hose.



Also, how the heck can you run a fuel line on the darn thing? It sits less than 1" from the bed crossmember! I put a 5/16" line on it and routed it the best way the the hose is pretty close to kinking and it's rubbing against the bottom of the bed.



What am I doing wrong? You all made it sound like it was a simple affair to hook it up to this port!



I'm thinking of making some sort of 90* outa some brakeline... or... I dunno.



Ideas??

 

[steved]

Can't help because my 3rd gen doesn't have that...



But I found the easiest way to install the line from the aux tank was by placing a peice of pipe (with a hose barb fitting installed in it) into the fill line (I actually used the piece from my FASS and installed another hose barb into it). I know you can get these from Northern Industries...



Don't use the vent as it must have a check valve in it to prevent fuel from running into the tank??



steved

 

[Joe G.]

I had mine like that for quite a while. No problem.

 

[Nate]

I was thinking of drilling a hole into the crossmember and running the line through the crossmember, though that would mean dropping the tank.



Whatever DC guy made that fitting right on top of the crossmember... #@$%!



I guess I need to find a barb fitting from 3/8" pipe to 5/16" hose and run 5/16" the whole way.

 

[B.G. Smith]

I don't know if the module is indexed to the tank or not but I would loosen the big plastic nut holding it in place and see if I could turn the module a little to clear the frame. I ran mine into the filler neck as stated above. bg

 

[steved]

I don't know if the module is indexed to the tank or not but I would loosen the big plastic nut holding it in place and see if I could turn the module a little to clear the frame. I ran mine into the filler neck as stated above. bg

It is indexed... if you turn it, the float will either read empty or full because it can't move (hits the side of the tank)...



Don't ask how I know this... all I will say is I drove for over 100k with a full tank of fuel... :-laf





steved

 

[FLynes]

What about a 90 degree elbow fitting?

 

[Nate]

Not enough room for an elbow. I had an old turbo wastegate elbow, 1/4", but I was just checking, and it wouldn't fit between the crossmember and the tank.



I'm half tempted to order that kit from Northern Hydraulics, but I really don't want to fork out the $75.

 

[BGlidewell]

http://www.valueplastics.com/ttt/ttt_fl_elbow_red.asp

???

 

[ProspectorTim]

Before you drop the tank, mark the spot on the bed crossmember where that hose hits it in your first photo.
Drop the tank, but instead of drilling it, lay a 1/2" socket extension across your mark and smack it good with a big hammer. You should end up with a nicely rounded indentation for your hose. No sharp edges, no bare metal to rust.

 

[RJWEST]

Browse napa/discount/etc. , look for a molded hose with a bend, may find something,
Or a 'YOU PULL' junk yard... just keep looking for a molded/curved fuel line.

 

[Nate]

I'm probably going to go over to Northern Hydraulics/tools (whatever they call themselfs these days) and get the adapter thing. I'm in Houston for a couple months and there's one just down the road from the hotel. will save me on teh shipping.



I've heard a few guys say the stock tank will flow over with the pressure from the aux tank... it's a PITA to fart around with this aux port as well when I know the Northern Hydraulics kit work nicely.

 

[DMcLeod]

Nate-I just used the aux port on my 01 last weekend. It was located just ahead of the crossmember, and my hose has a nice gentle curve coming up and away. It just seems to me that your module isn't rotated quite right on your tank (or else the design changed over the years). I know it's supposed to be indexed as mentioned, but possibly it was removed once before and not re-installed properly again??? I've never had one apart, though. Good luck.

 

[Nate]

Doesn't look like the tank has been pulled.



Northern Tools was sold out of the adapters when I went yesterday... the guy said they had about 5 the week before and sold the last one that morning. Wouldn't figure that much of a damand!

 

[KAlder]

When I worked at the local dealership I didn't drop the tank, I raised the front of the box to change the fuel sender module. so yours may have been changed or repaired by someone w/o dropping the tank.

 

[B.G. Smith]

Doesn't look like the tank has been pulled.



Northern Tools was sold out of the adapters when I went yesterday... the guy said they had about 5 the week before and sold the last one that morning. Wouldn't figure that much of a damand!

You can get a short bend 90% brass ell at Lowes and probably Home Depot and others. It is a Pex fitting (found in the plumbing dept. ) and barbed, I used some of them to plumb up my inbed tank. I may still have a couple I could mail to you. bg