Archived fuel return line replacement

[lbridges]

the fuel return pipe at the tank sending unit has rusted out. has anyone replaced it. I have rubber fuel lines but it is leaking on the return at the tank. The suction tube is not far behind. 1997 12 valve. thanks.

 

[kenny61]

I relaced mine years ago when I went to the dealerr for the fuel sender they sold me the whole unit for around $250. I have since learned the sender is sperate for around $30. 00. The last time I replaced the sender I noticed the lines were rusty and decided to just "fix it" I don't remember what i did but I was able to take a regular copper pipe fitting think it was about 1" or 1 1/2" copper cap that fit perfect in the the part i had to remove from the top of the pick up unit. I drilled 2 holes in it and soldered barb fittings onto it installed rubber fuel line coiled in the unit so it would work with the float for the pick up and cut off the factory quick connect and plastic hose and repaced with rubber hose and clamps. I would have just bought the p/u assembly but I had not realized it was rusting out until I had dropped the tank. The dealer did not have the pick up in stoch so I would have had to put the truck back together and taken it apart agin when the pick up came in. took me bout an hour or so to modify it. I planned on replacing it but its held for 2 or 4 years now so I pretty much forgot about it until I read this thread

 

[DFerverda]

This is what i used,worked good but look the module over and see if you can improve on just cutting the straw to fit. I would not gut the bottom of the module, ie leave the screen in place.
Vulcan compound turbo components, FireBall injectors, DrawStraw™, Big Line Kits, VP silicone boot kits, gauge installation components, metric adapters & fittings, FASS, Quadzilla, Edge,AirDog, DTT Trans, ISSPRO, HTT Turbo, AFE, Veg pumps,  brackets,
Dirk

 

[lbridges]

tanks for the help

I ordered a vulcan draw straw with single return. i hope it will do the trick. thanks.