Broken Fuel Return Line Help
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Broken Fuel Return Line Help
Hey guys, i was driving the 6.7 and got on the throttle a bit and suddenly lost power, I slowed down to pull over and noticed I could smell diesel and it sounded like my injectors were knocking. I Popped the hood and one of the plastic clips that hold the return lines is broken and has popped off. I was dumping a lot of diesel. I know I need a whole new return line but my question is would that low pressure line cause the truck to suddenly lose power and knock like that? I never got a low fuel pressure warning and the truck would still run fine unless I gave it quite a bit of throttle.
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Joined: Aug 2004
Posts: 37,887
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From: North Central Rural Sask.
The connector broke on my truck, pushing out some diesel when I would try to start it, and my truck wouldn't start at all with that line broken.
I would think once your line is fixed, everything would be normal.
Also, check out a place called accurate diesel in Michigan. On their website they sell just the connector so you don't have to buy the complete line from ford.
There is also an upgraded fuel filter kit that goes in place of the factory upper filters that is supposed to resolve the weak links. I posted about it a week or so ago and didn't get much feedback on here, so I don't really know how well they work.
I would think once your line is fixed, everything would be normal.
Also, check out a place called accurate diesel in Michigan. On their website they sell just the connector so you don't have to buy the complete line from ford.
There is also an upgraded fuel filter kit that goes in place of the factory upper filters that is supposed to resolve the weak links. I posted about it a week or so ago and didn't get much feedback on here, so I don't really know how well they work.
Hotshot
Joined: Jul 2013
Posts: 14,248
Likes: 2,180
The connector broke on my truck, pushing out some diesel when I would try to start it, and my truck wouldn't start at all with that line broken.
I would think once your line is fixed, everything would be normal.
Also, check out a place called accurate diesel in Michigan. On their website they sell just the connector so you don't have to buy the complete line from ford.
There is also an upgraded fuel filter kit that goes in place of the factory upper filters that is supposed to resolve the weak links. I posted about it a week or so ago and didn't get much feedback on here, so I don't really know how well they work.
I would think once your line is fixed, everything would be normal.
Also, check out a place called accurate diesel in Michigan. On their website they sell just the connector so you don't have to buy the complete line from ford.
There is also an upgraded fuel filter kit that goes in place of the factory upper filters that is supposed to resolve the weak links. I posted about it a week or so ago and didn't get much feedback on here, so I don't really know how well they work.
the upgrade kits use the same connector do there’s no fix there
FTE Legend
Joined: Aug 2004
Posts: 37,887
Likes: 20
From: North Central Rural Sask.
This is the upgrade I was talking about, and it appears to have the problem area addressed.
https://hs-motorsports.com/products/...=7149513801785
Is there another upgrade available?? I'm all ears if you know of a different one, i haven't bought anything myself and will be looking to upgrade eventually!
https://hs-motorsports.com/products/...=7149513801785
Is there another upgrade available?? I'm all ears if you know of a different one, i haven't bought anything myself and will be looking to upgrade eventually!
Tuned
Joined: Jul 2010
Posts: 287
Likes: 11
From: Alliston, Ontario
I was doing the filters for the first time today and broke that famous return line coupler '18 model. I ordered a new coupler / hose from Ford, it appears there was some upgrades made as there is a coupler is now supported by plastic retainers to prevent stress on that joint. The fact the Ford dealer had one in stock that has to tell you something.
That was a $200 mistake along with a few hours to change out the entire hose (not a fun job). In hindsight I probably should have just cut the coupler out of the new hose. Won't make that mistake again.
That was a $200 mistake along with a few hours to change out the entire hose (not a fun job). In hindsight I probably should have just cut the coupler out of the new hose. Won't make that mistake again.
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Well guys I got the new return line installed and everything buttoned up. Sadly I’m still fighting this thing. I have air in the system or it’s pulling air from somewhere. I can’t find any fuel leaks everything is bone dry. I have purged this thing 100 times it starts and runs fine, I have driven it all over but I’m still hearing what sounds like random air in the two lines right under the brake pedal that run to the secondary filter when driving, and KOEO I’m getting the primary filter/pump growl air sound. I have put my scan tool on it I’m getting perfect commanded pressure and actual rail pressure, all injector tests pass, power balance is great. I’ve looked at all the connections at the primary and secondary filters, put a mirror on top of the tank to check the sending unit lines, all look fine. I disconnected the return line at the secondary filter and connected a clear hose and I’ve ran gallons of fuel through that never seeing any air or bubbled just steady fuel stream. I’m lost at this point.
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Hotshot
Joined: Jul 2013
Posts: 14,248
Likes: 2,180
Well guys I got the new return line installed and everything buttoned up. Sadly I’m still fighting this thing. I have air in the system or it’s pulling air from somewhere. I can’t find any fuel leaks everything is bone dry. I have purged this thing 100 times it starts and runs fine, I have driven it all over but I’m still hearing what sounds like random air in the two lines right under the brake pedal that run to the secondary filter when driving, and KOEO I’m getting the primary filter/pump growl air sound. I have put my scan tool on it I’m getting perfect commanded pressure and actual rail pressure, all injector tests pass, power balance is great. I’ve looked at all the connections at the primary and secondary filters, put a mirror on top of the tank to check the sending unit lines, all look fine. I disconnected the return line at the secondary filter and connected a clear hose and I’ve ran gallons of fuel through that never seeing any air or bubbled just steady fuel stream. I’m lost at this point.
over tightening the filter housing unseats the oring
for all models, check to make sure the engine bay filter lines are all clipped in correctly.
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well I’ve triple checked the primary filter and all my line connections, I can’t see anything wrong with the connections themselves, and the filter is screwed on until it’s touching the stop. I went ahead and took it back off to make sure the filter Oring was good and it appears to be good and sealing I guess. Not sure what else to do at this point I’ve still got a pretty quiet fluttering sound right in front of the brake pedal that can only be heard In the cab. Im getting a new whining sound sometimes at idle, it sounds like it’s coming from the drivers side engine bay. Unless anybody else has any ideas I guess it’s time to take it to Ford and get ready for them to probably just diagnose it as cp4 failure. All of this started right after changing 2 injector to valve cover seals. Truck was perfect before that.
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