Hutch mod question
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Senior User
Joined: Apr 2010
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From: Cambridge, United Kingdom
Hutch mod question
Hi guys, sorry if this has been asked before (I did search but didn't come up with anything)
With the Hutch mod - what is the reason for making the fuel return like it is, instead of just letting the fuel drop back into the tank from the top? I'd just like to understand it more before I drop my tank, and since I'm having trouble finding stainless tube the right size here, I wondered if anyone has just left the return line short so it still isn't near the pick up?
Vehicle is a 2002 Excursion 7.3 4x4
With the Hutch mod - what is the reason for making the fuel return like it is, instead of just letting the fuel drop back into the tank from the top? I'd just like to understand it more before I drop my tank, and since I'm having trouble finding stainless tube the right size here, I wondered if anyone has just left the return line short so it still isn't near the pick up?
Vehicle is a 2002 Excursion 7.3 4x4
Cargo Master
Joined: Jan 2009
Posts: 2,800
Likes: 31
From: OKC, OK
Hi guys, sorry if this has been asked before (I did search but didn't come up with anything)
With the Hutch mod - what is the reason for making the fuel return like it is, instead of just letting the fuel drop back into the tank from the top? I'd just like to understand it more before I drop my tank, and since I'm having trouble finding stainless tube the right size here, I wondered if anyone has just left the return line short so it still isn't near the pick up?
Vehicle is a 2002 Excursion 7.3 4x4
With the Hutch mod - what is the reason for making the fuel return like it is, instead of just letting the fuel drop back into the tank from the top? I'd just like to understand it more before I drop my tank, and since I'm having trouble finding stainless tube the right size here, I wondered if anyone has just left the return line short so it still isn't near the pick up?
Vehicle is a 2002 Excursion 7.3 4x4
Senior User
Joined: Sep 2009
Posts: 341
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I finished the Hutch Mod last week. As stated above you want the return as far away from the pickup as possible so it doesn't pickup and air from the return fuel. I used steel line instead of Stainless. It should be ok to use as several have completed the mod with steel lines. Get your fuel level as low as possible. I emptied my take to just under 1/4 and the tank was easy to remove. I used winching straps to secure the tank at both ends and then lowered each end a little at a time to get the tank down. Putting the tank back in took alittle more time to line every thing back up. Good Luck...you'll like the results of this mod.
Hotshot
Joined: Jul 2008
Posts: 12,782
Likes: 2,142
From: N.GA Mountains
What they said^^^^. I'll add that discharging the return on the bottom of the tank will reduce fuel aeration in the tank when the level is low.
This mod is sooooo much easier to do by removing the bed - as long as the bolts aren't rusted/frozen. With an impact wrench, 10min and 4 guys, the bed comes right off!
I recommend using something like a WIX 33972 before the pump. Ya don't want (or need
) a restrictive filter before the pump. Anything more than 50mic is too fine and can reduce pump life.
The problem:
The solution - without the extension on the return line here:
Btw, steel or aluminum tubing is FINE on the return.
This mod is sooooo much easier to do by removing the bed - as long as the bolts aren't rusted/frozen. With an impact wrench, 10min and 4 guys, the bed comes right off!
I recommend using something like a WIX 33972 before the pump. Ya don't want (or need
) a restrictive filter before the pump. Anything more than 50mic is too fine and can reduce pump life.The problem:
The solution - without the extension on the return line here:
Btw, steel or aluminum tubing is FINE on the return.
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Senior User
Joined: Apr 2010
Posts: 176
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From: Cambridge, United Kingdom
Thanks for the replies
That makes sense to me about aeration in the fuel if the tank is low - I hadn't thought of that and couldn't understand why the fuel didn't just 'drop' back into the tank from the top.
Sorry, what do you mean 'bed'?
I've looked under my Ex and it has a metal cover protecting the tank, is that what you mean?
That makes sense to me about aeration in the fuel if the tank is low - I hadn't thought of that and couldn't understand why the fuel didn't just 'drop' back into the tank from the top.Sorry, what do you mean 'bed'?
I've looked under my Ex and it has a metal cover protecting the tank, is that what you mean?
More Turbo
Joined: Mar 2011
Posts: 683
Likes: 1
From: cincinnati, oh.
Thanks for the replies That makes sense to me about aeration in the fuel if the tank is low - I hadn't thought of that and couldn't understand why the fuel didn't just 'drop' back into the tank from the top.
Sorry, what do you mean 'bed'? I've looked under my Ex and it has a metal cover protecting the tank, is that what you mean?
That makes sense to me about aeration in the fuel if the tank is low - I hadn't thought of that and couldn't understand why the fuel didn't just 'drop' back into the tank from the top.Sorry, what do you mean 'bed'?
I've looked under my Ex and it has a metal cover protecting the tank, is that what you mean?
Fleet Mechanic
Joined: Apr 2011
Posts: 1,441
Likes: 6
From: Marseilles IL
Here is how I did mine. Steel line, brass compression fittings. Not ideal, butt better than it was. So far so good.
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Fleet Mechanic
Joined: Jul 2005
Posts: 1,800
Likes: 52
From: Southern Colorado
I put two milk crates under the tank of my F350 and shimmed them up with wood slabs, until the wood slabs touched the tank. I lowered the tank just an inch or so onto the wood, and then removed the wood shims and finally removed one milk crate. This method allows you to progressively lower the tank until you're sure you have all the hoses disconnected and that the tank is free to drop. I did this alone and with the bed on, so it's a bit more awkward that way.
Beforehand, I used an electric pump and sucked all the fuel out first into 5 gal jugs. The empty tank was no problem to move and manhandle.
Beforehand, I used an electric pump and sucked all the fuel out first into 5 gal jugs. The empty tank was no problem to move and manhandle.
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Senior User
Joined: Apr 2010
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From: Cambridge, United Kingdom
Will let you know how it goes - just got to find somewhere here that sells the tube - all I can find so far is the rubber/injection type stuff!
Hotshot
Joined: Jul 2008
Posts: 12,782
Likes: 2,142
From: N.GA Mountains
Between reading yer post and replying I forgot ya said it was an X! 
Here's how I dropped/raised the tank in my cab-chassis dually (same tank location):
I've gotta do the in-tank mods on the X soon - maybe this week, so I'll do a write-up on what we come up with for it.
Hotshot
Joined: Nov 2006
Posts: 11,286
Likes: 263
From: North of Greenville
I've used my hydraulic floor jack and a piece of plywood to R&R the tank in my Excursion. A second pair of hands is really helpful with the Excursion because the fit is pretty tight, and you have to be really careful to not pinch the fill tube hoses on re-install.
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Senior User
Joined: Apr 2010
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From: Cambridge, United Kingdom
Thanks for the help guys - I understand the fuel system a bit more now!
I was thinking of using a transmission jack under the tank while the truck is on a lift or over the pit in the workshop (luckily I can use a workshop evenings and weekends)
Just got to find somewhere here selling the tube now.............
I was thinking of using a transmission jack under the tank while the truck is on a lift or over the pit in the workshop (luckily I can use a workshop evenings and weekends)
Just got to find somewhere here selling the tube now.............
Cargo Master
Joined: Oct 2009
Posts: 2,500
Likes: 14
From: South Carolina
Effective, easiest to find and cheapest way to go is:
1) Steel brake lines, (cut to fit by you)
2) Compression fittings
(Can be found ot most parts stores)
3) SS clamps
4) 30R7 (or better that is rated for pressure)
5) Eliminate the foot.
6) Do use a filter similar to the wix 33972 near the pump
1) Steel brake lines, (cut to fit by you)
2) Compression fittings
(Can be found ot most parts stores)
3) SS clamps
4) 30R7 (or better that is rated for pressure)
5) Eliminate the foot.
6) Do use a filter similar to the wix 33972 near the pump
Hotshot
Joined: Jan 2011
Posts: 18,849
Likes: 179
From: Puget Sound
I used the hillbilly method: I added a length of tubing (about 2 feet) to the end of the hose in there and directed the tubing aft when I inserted the pickup assembly. My memory is fuzzy on this, but I secured the hose in a way to prevent it from touching moving parts.
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