Fuel Hard Line Leak

[crabman]

I have a hard line that is leaking along the frame rail. Any one ever had this problem before? The leak looks like it is located about 20 inches from the back of the cab @ the first group support block. I removed the the bed and dropped the fuel tank. There isn't any noticeable damage to either line but one of them is leaking for sure. Now I need to get the truck running or pressurize the fuel line, to make sure which line is leaking & exactly where it is leaking(pressure or return). Any ideas?
The FSM says to replace the gasket under the pump if it is removed. Is this a must do or can it be reused? Since I have the tank out, I am going to do the fuel vent bomb.
Any helpful ideas would be appreciated.

 

[CBari]

I just had one do it on my 04.5 it was closer to the tank and was easy to find. I ended up dropping the tank and put a union in it. I have about two 5 inches spots on my 03 that I removed the metal lines and tied them to an aux tank and switch. I have since removed the tank and just have about 10 inches of rubber hose on the metal lines with hose clamps no leaks for as long as it has been that way which is over 240K miles.

 

[crabman]

How much fuel hose did you slide over the hard fuel line? Did you single clamp each end or double?

 

[CBari]

There is about five inches slid over and I double clamped.

I am sure some of the purest on the the site will scoff at this type of repair, and I probably would have too, but the when I had the aux tank installed they did that and I never noticed it till 100k miles later. At that point I decided it must be alright.

 

[sag2]

I'm assuming you are talking about the 98 and not the 06. On the 98 you should at least double clamp it as any air leak will cause big starting or running problems. Since you have the bed off if it were me I would replace both lines while you can get to them. If you don't you know the other one will spring a leak next month, or right when they open the crab season!

 

[crabman]

It is the 06.
Not sure if they are going to have a crab fishing season. I sold boat & all my commerical crab gear years ago and am happy that I did.

 

[sag2]

If it is the 06 you should be just fine as the pump in the tank will make sure no air gets in the repair.

I was up in Oregon this summer and spent a couple days with an old friend that commercial fishes for white sea bass. He also gave up on crab, too much work.

 

[crabman]

"too much work."
From my experience he is 100% correct!

 

[frankbee3]

Hello, this is my first post as a new member of TDR. I am planning on buying a 2003 Dodge Cummins 4WD crew cab with long bed later this week. I am trying to locate a source for the fuel tank vent kit.

I have tried going to Spoolup's website and am getting a 404 message. I seem to be running into a dead end while trying to find the fuel tank vent kit.

Forgive me for barging in.

I hope to be driving my first Dodge Cummins truck on Wednesday.

Any help locating the vent kit would be greatly appreciated.

Frank Britton

 

[crabman]

Welcome! Glacier Diesel Power is the place and the following link will take you to the correct place. http://www.glacierdieselpower.com/gdept.aspx?dept_id=02

 

[crabman]

Hard line fuel leak update.
I removed the tank, wiped down the fuel spill area under the truck. Inserted some small pieces of paper towel around both fuel lines. Removed the fuel pump and placed it inside a 6 gal. clean plastic bucket, hooked up the fuel lines and electrical connector and put 3 gal of fuel into bucket. Hooked up both batteries and positioned myself under truck while my better half turned key to on position. Pump ran correct amount of time and ZERO fuel leak. Did this 3 times and still no leak. Started truck and let if idle, Zero fuel leaks, run up engine speed to 2k and held for about 1 minute, Zero fuel leak, paper towel was dry. So where was the leak coming from when tank was in place? Zero damaged to outside of tank any where. I cut out 10 inches of the supply line where the frame was the wettest. Slipped new rubber fuel line over the hard line(5-6")and doubled clamped each end(fuel line from Larry B's). Repeated the procedure that I had did before and no leak.
I reinstalled the tank and put 6 gal in tank, repeated procedure with same results. Put in 6 more gals. and rigged up my stop lights, turn signals and took it for a 25 mile drive @ 55-60 mph, no leaks. Added 12 more gal. and another 25 mile drive, no leaks. Filled up tank and did it again, no leaks. I inspected the cut out fuel line carefully and could not find any damage or imperfection.
I am going to drive it for several days before I reinstall the bed and rear bumper.
I am still not sure where the fuel leak was coming from as I did not find a creditable source for the leak.
The only good thing about this is that I did get the fuel vent mod done.