Engine/Transmission (1994 - 1998) Fuel Return in Tank

[JMarsh]

I changed the sending unit on my 95 and when I removed the return line from the tank I broke the plastic quick disconnect. The only fix I had was to connect the return line to the aux fuel port on the unit. The tank was about 1/4 full. When I got the truck running again, it ran rough going down road until I put more fuel in it. It acted like it was running out of fuel at times.



Has anyone done this? The aux line runs to the outside of the screen and thus filters all the fuel, where the old return line ran to the center of the pickup where the supply was.



I am going to run this tank down to see what happens when it gets low again, but wanted some input.

 

[JFaughn]

I am not familiar with a aux fuel port , I would suspect that your connecting to the vent .
On customers trucks & cars I would replace the hole sending unit , better job for the money spent , but I experiment on my own , what I have done in that case is find a piece of metal tubing that fits tight [ some times using drill bit to fit ] & the epoxy around it .

 

[JMarsh]

The aux port was listed in the service manual. It was capped off at the top. There is also a vent port which is still in tact. I tried the metal line, epoxy trick you mentioned, but it didn't work. I broke the plastic pretty good.

 

[tp0d]

When I redid my fuel lines, I ditched the quick connects and just pushed the hose over the supply/return nipples, and double hose clamped them in place. The hose wont go over the rib left by the quick connect, but as long as your surfaces are clean and dry, friction helps out here. I`ve been running mine this way for over 35k, with no problems. You can cut into the existing steel lines under the driver and couple to rubber from the tank, if you arent replacing everything. Use only high grade marine hose, I recommend Trident #365

good luck

-j