fuel return line

[Kalaehina]

Hey everybody, I'm getting ready to change the fuel return line on my 96 reg. cab 4x4. What's the procedure to do this? Should I move/remove anything before I start? Any tips (or warnings) from anyone who's done this before? I will be attempting this feat by myself without the help of my Dad, who's always been my mentor and savior when it comes to repairs, but he's out of town right now so it's time for me to go solo, so all assitance will be greatly appreciated!!!!! Aloha!

 

[Paul]

Unclip the metal lines at the bellhousing, that will let you move them around and get at the connections alot easier. I also used a Dremel with a small cut off wheel to cut the crimped on clamp at the injection pump.

 

[Joseph Donnelly]

Removing the quick-disconnect fitting does help some. One clamp takes a 6 mm and the other a 7 mm socket, as I recall on my 1997. They should be positioned so you can get on them with an extension. It is a pita but not technically difficult.

 

[Howard Durand]

Remove the starter and disconnect the front drive line at the differential so you can swing it out of the way. Both are quite easy to do.

That allows you to get your shoulder up higher and reach the hoses and connections easily.

Save the original clamps if you can, they are smooth inside so that they don't cut into the rubber and are better than most replacement clamps you get at the auto parts stores.

Good clamps can be found, mostly at racing supply stores, but they are expensive.

In my humble opinion, they are worth it. I had a bad experience with cheap clamps that the dealer used on my transmission fluid hoses.

 

[Kalaehina]

Thanks

Thanks guys for all the advice and help... I did it! Fuel line changed! Next time won't be so intimidating for me. Thanks again!

 

[HerbW]

Hi,

Hopefully you put diesel rated hoses in. The regular ones don't last long with diesel in their veins! I also hear that the marine hoses are the best and are sold at boat shops, etc. The bad hose, I bet, was the return one. Mine looked terrible like it had been stabbed all over it. The feed line looked brand new. I don't get it. Glad you got it done yourself! Herb