Hey guys. I am having real trouble with my 1990 F250.

I managed to drop the rear tank and found that the (i think it's the supply side of the fuel pump. it is definitely 3/8") line has multiple holes in the line. So I cut it and took it to NAPA, and he gave me the kit to repair it. (it is the one with the 90 degree fitting)

The quick connect part fits, but the fuel line still connected to the truck is just too small. I soaked the nylon in hot water and hit it with a hair dryer, but the fuel line to the truck is just too small.

is it possible that the line to the truck is 5/16" or smaller? I am stumped.

To say it another way, the pressure fitting is a 3/8", but the fuel line on the fuel filter side of the splice is much smaller. Maybe the nylon shrank?

I thought I would put it away for a day, too frustrating...

 

There should be TWO lines going to your fuel sender- one out, one return: The return line is smaller than the out line...

Scott

 

yes, there are two, but the best I can tell is only one is leaking. It is spraying fuel like a small bucket got dumped on top of the rear fuel tank. it is the smaller line which has the 3/8 hook up to the fuel pump, or the one on the passenjer side with the 90 degree fitting on the fuel pump, the other is straight.

 

sounds to me like reutrn line leak...5/16" return line and 3/8" supply line...however that was when it left the factory...whose to say what hands have been in it since...You can make up your own line using fuel injection hose.

 

yes, this is the problem, but the replacement part fits the fuel pump with a 3/8 quick release fitting, but when I try to splice it on the other end, to the fuel line, the fuel line is too small, even with soaking it in boiling water for 15 min. I hope I am doing a decent job of explaining the problem, it is difficult in writing.

 

I replaced all or most of mine with 3/8 rubber fuel line several years ago. No problems.

 

The only time I ever successfully got a push on connector on hi-pressure nylon fuel line was with a dedicated heat gun. I feel your pain. The fixit kit from the help section wasn't much help. I'd like to see a better solution as these things age.

 

So I like to clean up threads where I asked a question, because it will help someone someday...

I bought the 'help section' fuel quick connect (it was listed for GM and CHrysler, but it worked, and the safety clip even fits back on), and pressed on the in line splicer with a hair dryer and some vaseline. there is a good video on youtube. then I spliced some high pressure fuel injection hose, and followed the broken hose up to the y pipe where it fits on the frame rail which is also a 3/8 barb fitting.

My problem was, the nylon fuel line had shrank, and there was no way to get the 3/8" in line splicer on. I decided I was not going under the truck with a leaky cut fuel line and a heat gun. No way.

Now to fix the rear tank filling up the front tank, but that is a lower priority than an exploding fuel line. !!!

Thanks, community.