Engine/Transmission (1994 - 1998) Fuel Return Line Replaced with Marine Hose

[RT_Craig]

Just want to thank the members of this forum for the great information available. I developed hard starting behavior on my '96 and decided to tackle the dreaded replacement of the fuel return hose. The difficulty removing and replacing that short piece of hose is definitely one of the most challenging tasks I have undertaken. I spent 4 hrs on that project. I never could ever see where the hose connected to the metal lines above the bell housing. I wanted to take the starter off, but did not have the right tools. I am sure that would have helped. I did everything with one hand by feel from under the truck for the bottom connection. That was a major pain. I read about the recomendation to use marine grade fuel hose (SAE 1527 type A1)and opted to follow that advice. I feel confident that I will not have to replace that piece of hose again for many years. So far, the truck is starting right up. The original had many cracks in it and I saw evidence of fuel leakage on the bell housing. Thanks to all that posted info regarding how to replace it and what to buy as a replacement.

 

[illflem]

Consider you TDR subscription paid for. The dealer would have charged you $125 to replace one hose with the same kind of funky hose.

Now that I think of what a PITA it is maybe $125 is a deal.

 

[Dave Fleming]

Bill, I didn't know about the Fuel line problem and took it to the Stealer, they changed one line, the easy one at that! For about $150 USD. Within about 2 weeks smell came back. No Stealer for this one.

Took it to Cummins Cal Pacific and they knew right away what the problem was. I had just received my first issue of TDR and brought it with me to read whilst waiting.

Rather short mechanic comes out and asks for the keys. I ask can I watch from behind the yellow line, he says sure.

I am guessing he is their Fuel Line specialist. He removed the starter, brake master cylinder, fuel filter head, replaced BOTH hoses, said the Stealer had used gasoline hose NOT diesel grade hose! Took him just under 2 hours.

$250 USD poorer I am happy and out the door. Parts were about $4 USD.