Fuel Fitting Broke
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More Turbo
Joined: Oct 2020
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Fuel Fitting Broke
Man o Man....2021 is going to start off great......
I am swapping parts from my SD truck to an OBS motor so I can replace my bad SD motor. All was well until the fuel fitting that goes into the fuel port broke. I then used a bolt extractor and that broke!!!! It is stuck and it aint coming out, used the welder and no success. I have as much access as I can since the motor is out. I am pressed on time and here is my theory (see the 2 videos below, I did dumb it down for a friend but you get the point.) I dont have any shrapnel in the port and I dont have to worry about it sealing (in theory) because a solid bolt with some 620 loctite shouldn't even let fuel get to that fuel port.
Would this cause any issues? I know it isn't ideal but it can get the truck running and I will get a new head for it at another time.
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7.3 drama - YouTube
I am swapping parts from my SD truck to an OBS motor so I can replace my bad SD motor. All was well until the fuel fitting that goes into the fuel port broke. I then used a bolt extractor and that broke!!!! It is stuck and it aint coming out, used the welder and no success. I have as much access as I can since the motor is out. I am pressed on time and here is my theory (see the 2 videos below, I did dumb it down for a friend but you get the point.) I dont have any shrapnel in the port and I dont have to worry about it sealing (in theory) because a solid bolt with some 620 loctite shouldn't even let fuel get to that fuel port.
Would this cause any issues? I know it isn't ideal but it can get the truck running and I will get a new head for it at another time.
More 7.3 drama - YouTube
7.3 drama - YouTube
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Joined: Oct 2005
Posts: 6,129
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From: Ponca City, OK
I couldn't say whether it will work or not, but a bench test with air or possibly vacuum should confirm or deny for you. The injectors would need to be installed, but if it's air tight should be diesel tight.
More Turbo
Joined: May 2016
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I would suggest using Loctie 565 designed specifically for fuel applications.
I would drill and tap the port while having air piped to another port to prevent contamination of the fuel circuit; everything blows out the port you're tapping. When drilling, do it in sequential increases and try an extractor each time. Most often they will easily extract. I also suggest NOT using grease as it may trap particles the which the air can not evacuate.Brake clean or similar between drillings will help remove particles.
I would drill and tap the port while having air piped to another port to prevent contamination of the fuel circuit; everything blows out the port you're tapping. When drilling, do it in sequential increases and try an extractor each time. Most often they will easily extract. I also suggest NOT using grease as it may trap particles the which the air can not evacuate.Brake clean or similar between drillings will help remove particles.
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More Turbo
Joined: Oct 2020
Posts: 541
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I would suggest using Loctie 565 designed specifically for fuel applications.
I would drill and tap the port while having air piped to another port to prevent contamination of the fuel circuit; everything blows out the port you're tapping. When drilling, do it in sequential increases and try an extractor each time. Most often they will easily extract. I also suggest NOT using grease as it may trap particles the which the air can not evacuate.Brake clean or similar between drillings will help remove particles.
I would drill and tap the port while having air piped to another port to prevent contamination of the fuel circuit; everything blows out the port you're tapping. When drilling, do it in sequential increases and try an extractor each time. Most often they will easily extract. I also suggest NOT using grease as it may trap particles the which the air can not evacuate.Brake clean or similar between drillings will help remove particles.
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Joined: Jan 2005
Posts: 13,091
Likes: 4,702
From: Henderson, NV
@Hvyhaulr , to make sure I'm understanding you right, you're saying the factory adapters that screw into the head with a 1/8" NPT thread are stuck in there? And now there's a broken bolt extractor in there too? And you have tried welding a nut onto this broken fitting/extractor combo and it still won't budge? Did you apply heat to the head area before attempting to unscrew it? Drilling and chasing threads is a last resort in my opinion. If it comes to that, you may have to weld the hole up then redrill and tap a nice clean hole for the fitting. My experience with pipe threads is you can't clean them up enough after drilling to prevent leaks, especially fuel. You don't want to drill out the hole for larger NPT thread and then use a bushing because there isn't much meat in that area of the head and you could crack the head screwing a larger pipe thread in. Others have reported that simply screwing the 1/8" NPT adapter in too far has cracked heads that led to fuel leaks before.
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wb6anp
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