Engine/Transmission (1998.5 - 2002) vulcan big line complete kit-how long to install

[MJaynes]

hi all,i've just recieved the big line kit from genos. how long do you think it will take to install... . i'm not totally mechanicaly impaired,just partially. also, what tools do i need. thanks,mike

 

[Jefff929]

call Eric at vulcan performance



I'm sure he would answer any questions you have.

 

[Nate]

It took me a weekend to do mine, though I fabbed my own brackets and it was my own kit, so I had to make a wiring harness, fuel lines, etc.



The fuel pump doesn't have a whole lot of room to mount on the frame rail on the 2nd gen short box quad cabs... took me a bit of head scratching to figure a

good way to mount it.



Anyhow, I bet that Vulcan kit could be done on an afternoon without too much trouble.

 

[VIPERBLUELX]

took me about 2 hours on a lift

 

[mhenon]

It took me the better part of the morning. I did some extra work like removing the fuel filter housing and installing after market filters and mounts. . but it wasn't a tough job.

If you just do a standard install, the instructions from Geno's will be all you need.

Mike

 

[DonS]

hi all,i've just recieved the big line kit from genos. how long do you think it will take to install... . i'm not totally mechanicaly impaired,just partially. also, what tools do i need. thanks,mike

It took me a couple of hours, including a "tools run" for a tubing cutter.



An assortment of wrenches (combo, 1/4" and/or 3/8" sockets), a small tubing cutter (one that will fit between the factory fuel line and the frame rail just forward of the tank), some dielectric grease, and a knife are all that's really necessary, though a hair dryer may help when installing the fittings at the relocated pump. Maybe a few rags or small jars to catch the fuel that might spill when you cut the fuel line.

 

[Walleye mike]

It took me about 2 1/2 hours, that includeds retrieving the tools my four year old took out to the yard.

 

[Sageair]

About 6 hours for me,like mentioned above the short beds are a little tighter and take a little longer. Here is THE big tip. When you remove the fuel line supply fuel line ( the one coming from the tank)at the old lift pump. Take off your fuel filler cap and blow some shop air through that line. It will save you a fuel bath when you cut the steel fuel line. Thanks Eric!

 

[jandtjil]

Question the directions recommend a sealant be used, where exactly requires sealing and what did you all use?

JJ

 

[GCULP]

don't recall any sealant, all the connections should be push lock or couplings. get yourself one of those little thumbwheel pipe cutters, Home Depot for $8 to $15. and as suggested before, remove the fuel line on the pump side of the fuel filter and blow some air through the line and into the tank, tank off the filler cap so you can hear the bubbles, then be sure to re-prime the system real good before trying to start. should only take 2 to 4 hours depending on your skill level and Eric (Vulcan Performance) is usually availible for tech support.

 

[Fishin Guide]

My install was probably a little different than yours. But with all the pressure side lines changed to -6, install the 12Vavle lift pump, string new -8 suction line and install Vulcan Draw Straw, about 4 hours.



I used the factory steel suction line for return.



Dave

 

[jandtjil]

Excellent, Thanks fellas!

JJ

 

[KKohagen]

I put in the Vulcan big line kit. Took me a total of 2. 5-3 hours. The sealant I used was only on the 1/8" taped port off the elbow going to the VP44, per the kit instructions. I used copper-impregnated teflon tape, same thing we use at work, oil refinery process unit (Diesel/Jet Hydrotreater and Sulfur Recovery Units). The 1/8" tapped port then went to my fuel pressure gauge hose and on to the sending unit.
Since my pump relocation I now consistently read 15+#'s of pressure at the VP44, working on getting a higher reading gauge. Before I had 10. 5-11# and 8#'s at WOT.
All in all, follow the directions they work very well. Good luck.

 

[drag racer]

About 6 hours for me,like mentioned above the short beds are a little tighter and take a little longer. Here is THE big tip. When you remove the fuel line supply fuel line ( the one coming from the tank)at the old lift pump. Take off your fuel filler cap and blow some shop air through that line. It will save you a fuel bath when you cut the steel fuel line. Thanks Eric!

Boy are you ever right about that! I wish I had read this tip or thought about it more before I put my Vulcan kit on last month. I was not expecting it to happen, but when I cut my stock steel line, just about every drop I had in the main tank drained out - 15 gallons! Good thing I had extra empty fuel jugs, or it would have been a total disaster. As it was, I still had a little "lake" of diesel on the garage floor. :{

 

[benhall]

Mine took about 3 hrs with some help from Scrappy. One thing we did with my relocation was to loop the new small line from the point of cut, as to not stress the stock hard line.



Ben

 

[jandtjil]

Okay, I will starve as a mechanic!! about 8 hours including relocating the lift pump, but am completely satisfied. A minimum of 12 PSI, pulling the camper last weekend, like many of the TDR vendors, Eric at Vulcan cannot be beat.
Top notch individual!

JJ

 

[mmyers1]

Pushlock fittings

OK, call me dense, and yes I have done searches (that is how I found this thread! :-laf ).



I am installing the Vulcan Big Line kit and came up with a couple of questions. Is there anything special to do with the pushlock fittings? I read in the instructions to heat the tubing first... . but do the fittings, in your experience, need clamps? What exactly does the yellow ring do?



This is the first time my girl (truck) has required anything besides routine maintenance, so I am like a nervous parent I guess... .



Thanks for your patience and help!

 

[drag racer]

I am installing the Vulcan Big Line kit and came up with a couple of questions. Is there anything special to do with the pushlock fittings? I read in the instructions to heat the tubing first... . but do the fittings, in your experience, need clamps? What exactly does the yellow ring do?

The fittings do not require any clamps, although there is room to put some small ones on. Heating the ends help them go on a little easier as they are a very tight fit (hence, no clamps needed). The yellow rings are just plastic and act like a locating collar for the ends of the hose to insure the hose is installed fully over the barbs on the fitting. Be careful of the fuel siphoning issue that caught me by surprise and created a big mess.

 

[mmyers1]

It took me about 3 hours of actual work time. It took me about 5 hours clock time since I could not find my tight quarters tubing cutter and had to wait for a ride to come by and take me to HD!



Easy install. I was nervous at first, but it is as straight forward as they come.



One thing I did, that I have not seen anyone mention in any other post. Where I mounted the bracket for the lift pump, I removed the plastic clip that secures the steel lines. I cut the bottom portion off that supported the replaced fuel line then reinstalled it. This allowed the bracket to mount behind the clip, kept the support in place for the remaining stock lines, and looks good to boot.



I have pics if you are like me and need to 'see' it.



Mark