I have a 92 Ford F250 with an 7.3 IDI engine. The engine only has 114,000 on it. I recently had to replace the metal fuel lines as they rusted. So I used copper alloy brake line to make the fuel line. The sending unit on the front take had a leak and I couldn't find one to replace it so the shop used something similar to but supposedly much stronger than JB Weld to seal the leak in the sending unit nipples. The truck was running fine, until yesterday during a snow plow shift. The truck started fine Friday night on the way to the shop. I ran on the back tank to the shop switching to the front tank on the way since I was almost out on the back tank. I left it on the front tank after filling up. I turned it off when we stopped to get something to eat. When I went to start it, it started but I noticed that right after starting it had like a hiccup, I pushed on the accelerator almost at the same time of the hiccup and it smoothed out and ran fine. I turned it off a few hours later when we were just sitting. When I went to start it (still on the front tank) it started then stalled out roughly 2 seconds later. I tried starting it again and it just turned over but never started. I tried switching to the back tank and still nothing. I went out and used the bleeder to clear air out of the fuel system and it started. I turned it back to the front tank after it was running and it ran fine. We went to eat later on so I turned it to the back tank let it run for about a minute or so and turned it off. When we went to start it up it did the same thing, started for a couple seconds then shut off and I had to bleed air out of the fuel system again to get it to start. I am trying to figure out where it can be sucking air from.

At first I thought maybe it was something to do with the front tank since that is where the major fuel line replacement occurred (even though I drove it and started it while on that tank since the fixes), but when I tried to start it on the rear tank the last time it did the same thing so I think that rules out the front tank versus rear tank issue. Nothing else in the fuel system has had anything done this year so I am am not sure where else it could be coming from. I don't see any fuel leaks anywhere that might be sucking air.

I am hoping that someone might be able to direct me where to look. The injectors and injector pumps were replace three years ago and only have roughly 3,000 miles on them. This truck is only used to plow with and then just a little exercise during the summer months.

My concern is that while right now it stalls after starting and when I get it running again it runs fine, but will it get worse where it stalls during driving and not just at start up.

Thanks in advance.

 

if you are using the factory filter head, check for leak at fuel heater. and or you may have debris in the lift pump, holding open one of the check valves in the pump, all ways install a pre filter before lift pump to prevent this. 50 micron will do.