Archived Fuel Return line woes

[Loghead]

'97 2500 4x4

Line carrying fuel(return line?), one end is fastened to the forward and inboard side of the injection pump (P7100), connects to a rubber line (leaking)which passes over the inboard side of the fuel filter/water separator and down to steel line by the transmission bellhousing.

Miserable access. Idiotic design if you ask me (I design for a living).

The hose clamp on the inj. pump end is rusted closed. It's looking like I might have to remove the injection pump just to get this 50 cent clamp off:{#@$%! unless one of you fine folks have any ideas.



I'm thinking about switching to Ford if I ever get this beast screwed back together.....

 

[Alan Reagan]

Use a Dremmel tool to cut it loose.

 

[JFaughn]

Can you reach it with a pair of wire cutters ?
Going to a different brand just gives you a different set of problems , after working in the auto industry for 30 yrs , I found that they want to make excessive profits" screw us " [ a new definition of preventive maintenance ? and planed obsolescence ] after yrs of this it seems that they get together and figure out who's going to have a defective part , GM-computers & injectors , Chrysler-trans. , ford-subframes falling out of ft wheel drive cars - [ oops they messed up now GMs do that too ] ect.
Put that eng in the ford with an Allison , and your good to go .

 

[BigPapa]

Lots of reading here:



https://www.turbodieselregister.com...transmission-1994-1998/171159-any-tricks.html



Mine's still working 150K later.



Scott

 

[Loghead]

Thanks for the replies.

I like your approach BigPapa; I might do something similar, if not the same thing. I was looking at how the return line snakes under the intake manifold (or whatever it's called) and muttering to myself at how stupid that was when you could run it just beneath the injector lines and have good access to the fittings.

Maybe they figure it represents a fire hazard over the top. On second thought, the injector lines have far more pressure in them;so who knows?



I'm not switching to Ford; just having a bad moment. I've worked on enough Fords to know that even if fuel line placement is better, there will always be something else to give me a headache.



On the bright side, I've been reading that a leaky return line will cause hard starting, which my truck has been doing. At least I can expect to have that problem squared away once I'm done with this misery.



The sun has set, I'm done for now. I can sit back and watch my Red Sox get hammered. Top the day off appropriately.

 

[Flinty]

I just went through what you are going through 3 days ago. I ended up taking off the intake horn and the fuel filter canister to get it accomplished. While you are at it I recommend taking your fuel heater off, throwing it away, and cleaning your pre-filter screen. Pay me now or pay me later kind of a deal. Luck, J.

 

[JSimoneaux]

If you pull the plastic inner fender liner out of the truck and remove the driver's front tire all of those connections are easy to get to.

 

[Loghead]

Got 'er done...

Used a length of fuel hose ala BigPapa. I had to file a flat spot on part of the banjo bolt in order to flip it over (it was hitting the flange on the head of the inj. pump) and bend a slight "S" in the steel line to clear the injector nuts . To prevent chafing, I ran the 5/16 line inside a piece of 3/4 heater hose that's just a little shorter.

I wasn't able to find marine grade hose on short notice, but this setup will be so much easier to deal with (I can slide a leaky hose out of the 3/4 and slide in a new one in a few minutes) when I have to do it again. I can get marine grade for next time.



Thanks to all for your suggestions. This is what makes the TDR well worth the membership.

 

[Joe G.]

If you pull the plastic inner fender liner out of the truck and remove the driver's front tire all of those connections are easy to get to.

Not on a 4X4.