2004 Ford Expedition - 4WD - 4.6L
Ok. My blood pressure is a little high right now because I am not happy with Ford! I just spent the better part of one day and this evening trying to splice and cobble something together to replace my fuel filter. Five days ago, I started the truck and smelled gas. Result, leaky fuel filter. It was rotted and stuck so I had to cut the lines. In short, how do you splice LIVE nylon gas lines to new hose? I swapped everything out. New barbs to rubber hose to the filter. I watched the videos online and everybody shows a fitting, placed in a vice, and applying heat with a heat gun or a torch! You cannot do that with LIVE gas lines! I tried the hot water trick. It ain't happening.
Eventually, I found shark-bite unions for these nylon gas lines so I tried those. What really got me steaming was that everything that I cobbled together with rubber hose, barbs and clamps (aka 'old school') did not leak but EVERY shark-bite leaked. So, I would like to know what is the best way to mate an existing nylon gas line to new line? Whether it is nylon or rubber, how do you mate old to new? I am angry with any company that thinks that this fuel line was good idea.

Thanks,
Mark

 

You replace the entire line, not aware of a field repair. Sharkbite fittings are not rated for fuel and the nylon tubing is the wrong OD to be used.

 

Sounds like the cheap method is to pull the lines out and clean them then try the bench repairs you saw on youtube.
Expensive option is to pull all the lines out and replace them with new.
Either way you need to pull the lines out.

 

Autozone and Advanced Auto recommened them. They both had them in their fuel-line aisle.
This guy uses them too: