I have installed a new return line kit. I did each one individually then installed the hoses. I am still getting leakage. why are they just pressed on. also can I shim them so the inline nut presses them down. also is they a kit where they are already put together or is there a tip for installing theses caps. thank you for your replies and help.

 

Shimming them will not solve the issue. Did you use viton orings? That could be a problem if you didn't. What I do when I install return lines is I remove the old ones as a set and "build" the new set right beside it hose and all. It makes sure you get the hose on correctly and that it seals nice. You hold feel a pop when they are seated on. I wish they would have put a different type or return system on but this is what we got. Hope this helps.

 

Which return Kit did you use?

 

I found the biggest problem to be the clamps used for the hose. Decided to go with fuel injection clamps, which really helped.

http://www.ebay.com/itm/FUEL-INJECTION-HOSE-CLAMP-RANGE-7-16-1-2-1-4-HOSE-/190729850683?pt=Motors_Car_Truck_Parts_Accessories&hash=item2c68628f3b&vxp=mtr
Something like that, not sure what the hose size is on the return line for these engines though, either 1/4 or 3/8.

 

I just put a kit on mine that is a Dipaco (sp?) kit I got from Mel and it does not leak, so the quality of your kit could be the issue.

 

The Dipaco looks like a good kit, thats what I used on mine. just lube everything good with atf. I actually had to roll some of the orings on mine with a hook tool, so as not to nic them on the threads

 

I fought the plastic return caps leaking for six months. The aftermarket caps are garbage. The OEM Ford caps are superior in quality. The difference between the 6.9 & 7.3 caps is significant. The latter being the superior quality.

 

clamps were the biggest problem with mine after doing head gaskets, not enough tension, caps leaked for a little bit till they went through a couple warm ups. 3 months later still dry. that was a Pensacola kit.

 

I think that may be what the OP is looking for, you need to lube the o-rings, (some use Vaseline), before putting the caps on or they'll fight you.

 

I've always used Vaseline on the caps/o-rings/injectors/hose ends when I installed return caps. It always worked for me.

I recently had several leaks on hoses I got from Pensacola Diesel; the rubber broke down under the outer wrap. I bought a roll of fuel hose from NAPA and I'll try that on the next go around.