Engine/Transmission (1994 - 1998) Fuel Leak - Need Help With Hose Locations

[fleahead]

I've developed a substantial fuel leak coming from a rubber line that comes from behind and to the inside of the filter housing. I'm looking down on the engine from the driverside onto the filter. There is a bracket mounted immediately to the rear of the filter and toward the engine. A metal tube comes out of that bracket and it has a hose attached to that going toward the firewall. There is also a soft rubber line to the inside of the metal line going down to a smaller metal tube then to the firewall. That is the line that appears to be leaking, but up in the bracket. For the life of me, I can't see where the line is going after it goes forward thru the bracket or exactly where the leak is. I''m going to get some mirrors, but figured there would be someone familiar with what these lines are.

 

[Howard Durand]

I would guess that the leaking line or lines are one or both of the following. The one that feeds the fuel transfer pump from the fuel tank and the one that returns fuel from the injection pump back to the fuel tank. They both have a reputation of leaking due to cracking and checking with age and heat. The return line is the worst one of the two since it runs closer to the block.

It connects to the injection pump overflow valve at the top and near the front of the pump between the pump and the engine block and travels back to the area you are describing where it connects into the metal fuel line from the tank.

It is possible that the fuel transfer pump, pre-filter and heater assembly could be leaking. There is a rubber hose between the transfer pump and the heater housing.

In my opinion, the easiest way to be able to get to them is by removing the starter and dropping the front drive shaft. From underneath, you can see them much better and you will be able to reach up where the clamps are to be able to remove them.

If you have never had starter trouble, this would also be a good time to check the starter contacts.

 

[fleahead]

I believe you're correct about the return line. It appears to be cracked and aged. The fuel looks like it's coming from under the manifold, and running down the hose. From what I've read about this after doing a search on "fuel return" this must be a normal problem. I've also read replacement is a nasty adventure.

Thanks for the reply.

 

[Howard Durand]

These hoses have been a problem. I replaced both of mine several years ago. Since you have already done a search, you probably know the best type of hose to replace them with and the sizes needed. I believe the return line is the larger of the two.

Some of the advice given has been to cut the old hose clamps instead of trying to remove them but I removed and re-used the ones on mine. They are good quality clamps and are designed so that the screw does not cut into the rubber. I have bought several sizes of similar clamps to use in such cases and they are quite expensive.

There are a few different suggestions on getting to them from the top but I gave up and went in from the underside. With the starter removed and the drive line out of the way, you can really see everything quite well and have better access.

I used 1/4" drive sockets and a couple of long extensions to remove and replace the clamps with.

With the starter removed it would be easy to check the contacts and possibly replace them with a set of Larry B's extra heavy duty ones.

They have been known to stick closed and cause expensive damage.

 

[Joe G.]

You can also get a heavy duty fuel hose replacement kit from LarryB at http://www.fostertruck.com/dodge/default.htm

 

[KevinH]

i replaced my friends about a month ago and then mine started leaking a week later. all i did was remove the fuel filter and fished my hand under there with a (i beleive a 8mm socket) it only took me 15min.

 

[RON'S RAM]

I replaced mine from underneath with the starter removed. Really not that bad of a job.

 

[hsmith]

If you do not want to remove the starter, unbolt the master cylinder and lay it to the side. Remove the fuel filter, then you can see them. Use good hoses.

 

[fleahead]

Yep... got 'er done! Wasn't nearly as bad a job as I've been reading about. I removed the filter and got it done from the top. I did NOT reroute the new line up by the manifold however. Another thing, I checked at NAPA and an industrial truck repair garage, and both said there is no such thing as "diesel fuel" line. Fuel line is fuel line. Anyway, I may be doing this again in a few years???



Thanks for the suggestions. TDR has been well worth the fee.

 

[Joe G.]

Another thing, I checked at NAPA and an industrial truck repair garage, and both said there is no such thing as "diesel fuel" line. Fuel line is fuel line.

They sang me that song too. The replacment lines failed. I now have LarryB's fuel lines on mine. No sign of a problem with those.