Engine/Transmission (1998.5 - 2002) Fuel leak @ that crappy T fitting

[proflow]

Hey guys, I've been leaking fuel @ that T fitting near the filter (return line) for awhile now , just enough to barely tell, but progressed into hard start due to loosing prime. Now it's time to do something about this little junction of crap. I tried to tighten the three fittings , they will loosen very easy just after tightening. I really dont want to put new crappy little o rings in there either if it has them. In the past I've done Geno's Banjos, did the lift pump relocate recently . Now its time to fix this for good. I searched quite abit & seems some are having problems w/that rear line cracking. How bout a sweet barbed T fitting that'll except 5/16 ? marine fuel hose & get rid of the crack prone line & those junk compression fittings? Has anyone upgraded this yet ? I still need to obtain larger fittings for the vp pump to filter also, but thats another deal. Any help or tips would be greatly appreciated---Proflow.

 

[proflow]

Come on guys, anyone done something about this junction of fuel waiting to leak yet ? I love the smell of diesel, but dont like to crank :-laf Thanks--Proflow

 

[rweis]

Well,



I cut my return line right about 3" AFTER the T and put fuel hose on it with 3 small hose clamps. Has held well for about a year.



I cut mine and took the DC return line out because I run my return fuel through frame mounted fuel coolers.



The only thing I know about the return fuel is the higher the rpm the higher the volume. You do NOT want to block the return line (keep it full free flowing) I think the MAX psi is 10 psi. I remember reading that the return fuel can get as hot as 250* right out of the VP44. However I do not believe that figure. I monitor my fuel temp and VP44 temp and it typically is OAT +10*, but I do have fuel coolers on the return line as stated above.



When I took the T apart I found that there is a compression packing in the fitting. I seemed weird at first until you found the compression packing that it would give resistance to disassembly.



Good luck with it.



IF it was leaking I would be suspect about something clogged in the return line. It should be pretty free flowing. I free flow mine back to the tank vent line so I get the whole tank involved with absorbing the Vp44 heat generated.



BTW, the concept of using the fuel as a coolant is utter bs. As you get to the fuel low light, you also get to less and less cooling because the volume of fuel to cool is less and less. Of course if you ran with a full topped off tank all the time it would have less impact :-laf .



Bob Weis

 

[proflow]

t-fitting

Thanks for your reply Bob, Id like to upgrade to something less leak prone than factory. Im digging into it today & we'll see. Thanks again--Proflow

 

[rweis]

Well, I used the SS braided AN-6 line and hose clamped it to the factory return line. You could take it right off the VP44 and right off the injector return line and then combine them or NOT combine them and run them where ever you want. My T was not leaking so I used the output of the T.



1. The T just has packing cord in it, what about digging out the existing packing and replace it?



2. Cut each line (VP44 return, injector return) and run them seperately back to the tank. Then you have total control on each line.



It is a tad snug getting to the T. What I did was undo the T from the injector return and from the VP44 return and get the T on the workbench where you have some ability to modify it.



If you think it is primarily the VP44 return (where the volume is) that is leaking then cut that one and run it seperately to the tank. The injector return is very very very minimal volume I think. I think I remember that the injector return is for the tiny amount of excess fuel from the injector fuel lubrication.



Good luck. If I can help in any way call me (863. 206. 3464) and Ill describe in detail what I did with mine and the feel of getting the T apart.



Bob Weis

 

[klaybus]

Does a 99 24V Cummins have this same setup? The 99 vs 02 have different fuel filter housings & I'm having simular starting issues with my 99 on the first start of the day...

Please keep us posted on your results. I need some HELP on this one.



Thanks,

Clay

 

[proflow]

I took the vp side loose, theres a rubber sleeve to seal it up. Looked like new so I dunno. Im going to take the return offf & shoot some air into it w/cap off to see if its plugged. ---Proflow

 

[DavidC]

Does a 99 24V Cummins have this same setup? The 99 vs 02 have different fuel filter housings & I'm having simular starting issues with my 99 on the first start of the day...

Please keep us posted on your results. I need some HELP on this one.



Thanks,

Clay

Take a look here. Yours should be the same. Scroll down and there is a picture of it.



http://turbodieselregister.com/forums/showthread.php?t=123273&highlight=fuel+leak+head



Dave

 

[klaybus]

This will be my next location to look for a fuel leak if fixing the guage line didn't do the trick... ... I'll be taking a look at this area tomorrow after work when I start the truck for the 1st time of the day.

Thanks for the heads up Dave!



Clay

 

[ToolManTimTaylor]

Yep mine has been at that point for some time now. To the point that If my truck faces down hill it will start like it was new. Face it uphill for any more than half an hour and I can crank the daylights out of it as if I put in a new set of injectors and fass all in one shot LOL. Yet it can sit facing down hill for a week with no issues. I notice the T is wet and is my next target.

 

[proflow]

New Findings

After a more thouough inspection I found 5 & 6 Fuel stick connectors leaking. Just barely but probably explains loss of prime & hard start. I'll know if this is the case in the morning. I also found a leak in the quick disconnect for the return. So I axed that connection & slipped some 5/16th hose from one end to the other. No more quick disconnects. Only concern I have is I used 400 psi Goodrich trans cooler line. Dunno if thats ok w/diesel but it was in stock in my shop @ the time so I packed a fire ext. in case. We'll see tomorrow ---Proflow.