2nd Gen Non-Engine/Transmission Fuel Leak @ Tank - Help!

[MStearns]

I thought I had been smelling fuel after I shut the truck down over that last month. The return line is spraying fuel right where it enters the fuel tank. The supply and return outlets are both corroded and flaking off chunks of rust.



First order of buisness is I can't seem to find a replacement anywhere. I was hoping someone could point me in the right direction. I desparately need to get this thing running!



Also, I'm curious if I can replace the outlet assembly without dropping the silly tank. I just filled up. Depending on how long it is, it looks like there just might be enough room to swap it out... Assuming I don't have to pull the entire fuel tank module.

 

[JCyrbok]

I thought I had been smelling fuel after I shut the truck down over that last month. The return line is spraying fuel right where it enters the fuel tank. The supply and return outlets are both corroded and flaking off chunks of rust.



First order of buisness is I can't seem to find a replacement anywhere. I was hoping someone could point me in the right direction. I desparately need to get this thing running!



Also, I'm curious if I can replace the outlet assembly without dropping the silly tank. I just filled up. Depending on how long it is, it looks like there just might be enough room to swap it out... Assuming I don't have to pull the entire fuel tank module.

Not positive but I think that the entire module will have to be replaced, even if it is just the return fitting that rusted out and last I heard the dealer was the only place to the module at. From what I hear this is a common occurance (I'm waiting for mine to rust out here in Michigan with the all the salt that they use in the winter).



As for doing the work with out dropping the tank your only other option is to remove the bed either way I think dropping the tank or lifting the bed has to be done to get to and remove the module.



Hopefully someone else who knows for sure will answer.



J-



edit: here is a link to a thread that I found that looks like it will help. https://www.turbodieselregister.com...sion-1994-1998/190800-fuel-lines-my-96-a.html



If you search here at TDR you will likely find more that enough reading to figure this out.

 

[Joe G.]

You can install a Draw Straw in your module. Look here: VULCAN PERFORMANCE - DRAW STRAW I ('94-'04)-Dodge Cummins Diesel Truck Accessories – Geno’s Garage

 

[BarryG]

I am not positive if it will fit in a 96 tank (I know it fits in an 01 tank as I have one) but Vulcan Performance sells the Jeep Liberty Module for approx 100. 00 and it includes the complete module, fuel level sensor, float etc. They also sell the modded Liberty cannister with a draw straw already installed for I think 200. 00. Would be worth a look iirc the ram module is in the 400. 00 range.



plain jane version

DrawStraw™ V HiFlow



draw straw version

DrawStraw™ V HiFlow



On my 01 it was just a drop in affair and has worked perfectly. You will not be able to get the module out without dropping the tank or lifting the bed as it is too tall.

 

[MStearns]

Got a Draw Straw ordered from Geno's yesterday. We'll see how fast 2nd day shipping can get it here. It definately looks like the best way to go!



Now the question is whether to drop the tank or raise the bed... . Think I'm going to raise the bed. When I replaced the sending unit last time I just ran it till it was almost empty and then dropped the tank. But I just don't have enough containers to siphon the tank of into and really don't want to go and buy 7 or 8 new gas cans.

 

[SRath]

Free diesel!!!

Call your best buddy with a diesel truck and tell him "Happy Birthday!" and hand him the hose... (How close are you to Iowa?)



I would lift the bed, too. In fact, though I have no fuel or air leaks (that I know of) yet, I soon will judging from the corrosion on those el-cheapo factory lines and plan to remove the bed to do some further underbody shielding and thorough rustproofing anyway come spring. My fuel gauge is acting up lately, too. And I need paint. And a couple dents pounded out of the thin wheelwells where the previous owner must have had a hard time hooking to his gooseneck. . (Hmmm. Sounds like I have more reasons to remove the bed than keep it on... ) :-laf



Not only does lifting the bed look easy (it is, I have done it on many Chevys and they were much heavier), those corroded fuel tank strap bolts are just waiting to ruin the day I become foolish enough to try to remove them.

 

[MStearns]

Actually, I am just across the river in Papillion, NE (Omaha).



I too need to probably do some undercoating but the the time being I think I'll just remove all the bed mounting bolts except for the last two. With those last two loose I will jack the front of the bed up and brace it so I can get the room I need to get the fuel module out. If it were a little warmer out I could take the time and spray some undercoating but that will probably have to wait till spring!

 

[SMorneau]

I replaced the entire unit and then reworked the flexible lines that run from the tank to the hardlines. I did this by using approved diesel fuel line and some new connectors that are barbed into the lines and quick connect to the tank fittings.

I also let a loop of the lines on top of the tank so when I have to drop it down in the future I do not have to unhook the lines until there is ample space to see what is going on. I also coated the metal parts with amsoil MP heavy duty to keep the corrosion to a minimum. I don't have the exact connector part number but one close is Napa 730-5621.

 

[MStearns]

It's fixedOo.



This time I ended up lifting the bed. I removed all the bolts to the bed except the last two and then took my floor jack and a 2x4 and jacked the front of the bed up. It allowed just enough, but certainly not any too much, room to get the job done. If I had had an extra pair of hands I would have removed all of the bolts and just slid the entire bed back to gain access.



Installing the Draw Straw straight forward enough. The directions that came with it were very basic and not very good. Rather than following them I headed to the hardware store and grabbed some fitting to build a 1/2" to

5/16" male to male adapter. This way I integrated the draw straw into the fuel module without removing any of the filter screens and left the fuel feeding system stock. This way I won't have to worry about potential fueling issues when the tank is low



Can't wait to see what milage looks like now that I'm not dumpung copious amounts of fuel overboard!