Hello all, I recently bought a Motorcraft fuel filter for my 2002 F-250. The O-rings that came with it don't appear to fit. They were way too big. I ended up using the old one, and now have a leak.

What did I do wrong? FD-4596 is the part number, Fuel/water seperator.

 

I'm not sure what you have going on there -- did you make sure all the old O-rings came out? The center one can stick on there if you're not looking for it. The cap O-ring goes on what I think is in a counter-intuitive way. The bevel looks like it goes the wrong way, but it seals.

 

What's the Motorcraft part number on your new filter?

Pop

 

Me too. I've had that happen on the last two NAPA fuel filters I've purchased. So I kept using old gasket.

 

I have noticed that the new O rings are always a little bigger, but it always works. I would try and use the old one. When you put it in there try to smush it in there and then put the lid on, worked for me three times now.

 

I looked and it doesn't look like it is leaking from the filter. I do see a puddle of fuel right under the turbo and the leak definately started after I changed the filter. Now I smell diesel and can see the puddle.

Do you think I loosed anything when I unscrewed the fuel filter cap? What can I check to see, or tighten?

I am going to clean it as best as I can and see if I can see where it's leaking from. Maybe one of the lines going into the filter?

 

You may have the O-rings in the drain valve leaking.

It's a cheap, easy fix once you get the new rings.
See: Replacement O-rings for Diesel Engines

Pop

 

sorry mispost

 

Thanks for the info! I can't see anything that may be leaking. It's very hard to see up there! I'm 6'6" and even standing on a stool I can't see it very well.

I'll try to see if the drain valve may be leaking.

 

Most likely your drian valve "O" rings are leaking. Mine started leaking yesterday. Had a puddle of fuel on the ground and in the engine valley. Fuel smell coming into cab. Inspected and found the drain valve all wet with fuel on the outside. Ordered the "O" ring kit today.........Jeff

 

Get a flex mirror and a bendable stem, LED super bright light. ( got one at Harbor freight for cheap and now I cant stop bragging about it)

 

Izzy351 is right on. I always have to double check the oring for correct position.
Your fuel bleeder valve may be leaking. Easy quick fix. I picked up and I think is has 2 bolts on the side. Replaced and hadn't leaked for 3 years now! Knock on wood.

 

Yeah, I think I got all the orings out, can't remember now since it was few weekends ago. My new o-ring was way too big to use. Or at least I thought so.

Now that I think of it, I had a small fuel leak for a while now, never enough to drip, but enough to make a trail down the front of the tranny.

I'll check my drain o-rings since I also have a small puddle in the valley now, and diesel smell in the cab.

thanks for the tip about the mirror.