Engine/Transmission (1998.5 - 2002) Fuel Leak at Banjo Bolt on Fuel Filter Housing

[EGaskamp]

Last night night I finally figured out where my MASSIVE fuel leak was coming from. It's on the banjo bolt that goes into the fuel filter from the LP. I couldn't find the exact washer with the rubber o-ring inside it so I used something similar except it was a little bigger but the o-ring fit snug around the bolt. I started it and it still drips pretty good. Are these washer/o-rings only availible at the Dodge house or the Cummins shop? The leak is so bad that on the back of my tail gate I have fuel splotches! My brother was driving behind me the other day and had to hang back because he was getting fuel all over his windsheild! Has anyone had problems with thes washers? Thanks in advance.



Eric

 

[XJJoe01]

Sounds like a great time to buy a FASS!!



Seriously, Cummins and the dealer should have the o-ring washer. Just make sure the filter housing isn't cracked where the banjo bolt attaches.



Joe

 

[keimmmo]

I hate banjo bolts! They tend to leak and do not flow well. You can probably get the washers any place that does diesel injection work. Sometimes just turning an old one over to change the pressure points will stop a leak. As much as you are leaking, I have to wonder is something is cracked or broken. Banjo bolts often drip, but it sounds like you have way more than just a drip!



I would vote for relocating the factory pump just ahead of the tank and using a big line kit with straight fittings. (Vulcan or similar kit or home brewed. ) Your lift pump and injection pump will both thank you for making the mod!



Steve Keim

 

[EGaskamp]

It does sound like a perfect time for a FASS! Unfortunantly my pocket book disagrees :{. I will have it someday in the near future though. Ya'll scared me by thalking about the housing being cracked. The thing is, it's hard for me to see back there. I will check it out though. Once again, with the FASS I will have no worries! One more thing, With the big line kit that gets rid of the banjo bolts, is it just a male end that had the fitting that slides up and down the line and just screws in? That might sound like a dumb question. I've never seen a big line kit up close. Thanks a lot guys for your help!



Eric

 

[Fogie]

I did the Vulcan Big Line Kit the other day. Took me about an hour and a half. Straight fittings with sealing washers, hose clamps, wiring extension. Follow the instructions and it goes very well. Relocating the lift pump is part of the kit. Took more time to take the the pump off that it did to do the rest of the job. PITA location. Took the fuel filter canister off for much easier access. Well work while for me.