Archived BAD! Fuel leak!

[Got Smoke?]

I have a REALLY bad fuel leak. Like forms a puddle on the ground in just a few minutes. I thought I had been getting crapy mileage now I know why.



Now I need suggestions on where to look. Also truck will not start on its own anymore, you have to blip the throttle while cranking the truck to get it to crank and it stutters a little as soon as it catches.



I'm REALLY worried about this guys, and I need to get this fixed ASAP! HELP!

 

[Woodenhead]

What area is it leaking from. Last and only bad fuel leak I had was the return line. Undercoated the entire underside of my truck with fuel. Didn't make my truck hard to start though.



Mike

 

[Got Smoke?]

Well I shined a flashlight on it when I got home and can see a wet spot on the side of the motor ahead of the bellhousing is the way I can think to describe it.



A better way to describe it might be that its back in behind all of the fuel filter canister, but going straight down from behind the canister area. I cannot see where its leaking FROM being dark outside! I did try to turn the fuel canister and its tight, and the drain lever is also in the correct "closed" position.

 

[Josparkz]

Sounds kind of like that famous rubber return line in the back of the engine. Real pia to get at (unless the head is off)makes the engine lose prime.

There are a lot of old threads about it. You can drop the brake booster to get at it a little better, some folks say the starter also.

 

[Got Smoke?]

Will find out tomorrow. I fear its the return line and I am tight for $$ to get it fixed. I am going to have it looked at by a guy who knows Cummins pretty well though. Thanks Josparkz & Woodenhead

 

[Josparkz]

The thing about it is, it is like a $2 piece of hose.

The first time mine leaked, It was under warranty.

When I had the head off, it was staring me right in the face so I changed it then too.

There are massive threads in the archives here on that. If you work at it for a couple of hours and pull a few items loose out of the way, it shouldn't be too bad .

 

[Woodenhead]

When mine leaked I was on the road and actually stopped at a Case tractor dealer. Their mechanic had never done a return line before and had it fixed in about 45 mins.



It's certainly not comlicated, just a PITA to get at.



Long skinny arms help working mainly from underneath in a real awkward position. Like Josparkz said, give yourself a couple hours (1 for cussin' 1 for workin ).



Mike

 

[socal_rattler]

You might also check the o-ring inside the top of the fuel filter housing... mine had a crack in it one time and fuel sprayed out of it in a small stream.

 

[guns101]

Speaking from experience, it does sound like the return/supply hoses. I had mine done by a mechanic when I first bought my truck. Not knowing much about these cantankerous beasts. Left much fuel on the ground undercoated the truck and it made it as far up as the top of the heads and was pooling in the freeze plugs. Dripped so dang much off the left side of the bell housing, I could not see where it was dripping from. Mech replaced with all dodge stuff. even the metal loop was leaking. Just helped my buddy do his,due to hard starts. no leaks. We ripped out the metal loop on the bell housing and went with all fuel hose,diesel rated uscg approved gates hoses. about 3- 4 feet of each size. chopped into the metal lines on the frame and no more leaks or hard starts... until his fuel shut off relay pooped out this week... lol Time for me to do my hoses again. It never ends:--) :{

 

[JerryTurbo]

leak but no leak

Check the filter drain valve, it will stick open. push down on the top of the lever and open and close it with force on the close. I bet that is your problem.



Oops, I should of read more, you say fuel leaking rear of filter housing.

 

[Joe G.]

There is another place where I had a bad fuel leak. It all ran down behind the fuel filter. The return manifold pipe from the injectors goes between valve covers 5 and 6 to the same banjo fitting where the fuel line from the lift pump attaches to the filter. It is actually, two banjo fittings stacked. I replaced the four washers in the fitting and the leak stopped.

 

[Got Smoke?]

Goes into the shop to get fixed tomorrow. Got a pretty knowledgable diesel guy working on it, but he's mainly worked on 24V's. I would do the fix, but I'm losing A LOT! of fuel and don't have time to fool with it I NEED MY TRUCK. :{

 

[Got Smoke?]

Well the guy I took the truck to today says my injection pump is leaking. I'm not so sure its the injection pump, so I called up the local dealer and said "this is what I got how much to look it over" NO COST to look at my truck, figured out whats wrong with it, and quote me a fix price.



Now I know the fix price will be at the dealer, and I'm prepared for that. However my other guy was talking about taking my pump off and sending it to Nashville to have new seals put in I know he's never taken a 12V pump off so I'm leary and want to get the diesel guy at the dealer to look it over first.



I'm also printing this thread off to take and show him in the morning to help with trouble shooting.



Oh yeah... my tailgate and bumper are a MESS! They are filthy with fuel/dirt. 3/4 of tank gone, only drove 300 miles!

 

[Joe G.]

There is another place where I had a really bad fuel leak that is easy to fix and cheap. The manual push button on the lift pump has a large O-ring. If this is the leak, remove the rubber cover off the push button. Unscrew the push button assembly. Be careful, it's plastic. Take the large O-ring off and get one from NAPA that is the closest match. It cost me 51 cents.

 

[Got Smoke?]

PROBLEM SLOVED!



Dodge found the problem and believe it or not it seems like a lot lower priced than I would have figured from the dealer.



Seems the metal part of the fuel return line cracked!



So they are replacing the metal AND rubber parts of the fuel return line. Oo. However it will be Friday before they can get the metal line, and they said PARK IT! So I'm driving a friends little sisters camaro that he's trying to sell till Friday morning! :-laf

 

[Kalaehina]

Oo. Oo. Oo. Oo. Oo.