Fuels lines 6.9
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7th Gear
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Fuels lines 6.9
Hello all. This should be simple. I have a fuel leak at the tank switch. I haven't figured out if it is the switch or the line yet. After a few hours I have decided that I want to replace all the lines going from and to the switch. Is there any reason why I cannot replace all the lines with rubber fuel line and use hose clamps where needed?
Thanks.
Thanks.
Last edited by gironha; May 21, 2025 at 10:37 AM. Reason: typo
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From: Western Mass
If the lines are the stock nylon (plastic) ones, they pretty much last forever, why would you want to replace them?
If you have metal lines, replacing would be a good idea if they are rusty.
I believe you can get new ends for the nylon lines. There is a o-ring of some sort in them that could fail with age, I don't know how easy that is to replace. Do all the lines have the little plastic clip to hold them in place? Its either white or black depending on the size of the line (supply vs return)
If you have metal lines, replacing would be a good idea if they are rusty.
I believe you can get new ends for the nylon lines. There is a o-ring of some sort in them that could fail with age, I don't know how easy that is to replace. Do all the lines have the little plastic clip to hold them in place? Its either white or black depending on the size of the line (supply vs return)
Fleet Owner
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From: Mi'kma'ki
I replaced all my factory steel fuel lines with rubber hose on my F250 back in '09 as soon as I bought it. Been issue free since. I used Goodyear SAE 30R7. The rubber hose slides right on the plastic tank lines w/ clips too. I think there's an outer layer I had to strip back if I remember right.
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7th Gear
Joined: Aug 2015
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If the lines are the stock nylon (plastic) ones, they pretty much last forever, why would you want to replace them?
If you have metal lines, replacing would be a good idea if they are rusty.
I believe you can get new ends for the nylon lines. There is a o-ring of some sort in them that could fail with age, I don't know how easy that is to replace. Do all the lines have the little plastic clip to hold them in place? Its either white or black depending on the size of the line (supply vs return)
If you have metal lines, replacing would be a good idea if they are rusty.
I believe you can get new ends for the nylon lines. There is a o-ring of some sort in them that could fail with age, I don't know how easy that is to replace. Do all the lines have the little plastic clip to hold them in place? Its either white or black depending on the size of the line (supply vs return)
Didn't know about the o-ring. Do the lines just pull off after the clip is half way out?
Thanks.
Last edited by gironha; May 24, 2025 at 01:44 AM. Reason: typo
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7th Gear
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Yes, they have the clips. They are the nylon lines. The clips are positioned so that they can not be removed. If they only need to be pulled out to a loosened position, that would be fine, but I still haven't been able to get a single line to come off the switch. Not knowing how to remove them is a big part of the problem. In any case, I was assuming that if one is cracked and leaking, I only want to do this job once. Hence the desire to replace them all if necessary.
Didn't know about the o-ring. Do the lines just pull off after the clip is half way out?
Thanks.
Didn't know about the o-ring. Do the lines just pull off after the clip is half way out?
Thanks.
I just remembered today that I had worked on this 8 years ago and had the tank down. (It wasn't leaking back then). I was looking into replacing the sender unit because the tank is empty when the gauge still shows a 1/4 tank. I can live with that but if a sender unit is available I would like to replace it. 8 years ago I was told that the part is not available. Anyone know if such a part can be found? And where to get replacement clips if I go that route?
Thanks.
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Logistics Pro
Joined: Jun 2017
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From: Edmond, OK
The fuel line clip should pull straight out. All you need is a small flat bladed screwdriver to pull up on the clip.
You can get the correct fuel sending unit from LMC Trucks.
https://www.lmctruck.com/?srsltid=Af...XnBmyJdsjm23d8
You can get the correct fuel sending unit from LMC Trucks.
https://www.lmctruck.com/?srsltid=Af...XnBmyJdsjm23d8
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From: Mi'kma'ki
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From: Western Mass
There is a little tab that hold the clip in place, that prevents it from just pulling out. Sometimes you can get at it to push the tab in so the clip slides out easier, other times you have to wrestle with it and break the tab or snap the whole thing in half. Get replacement clips. Spinning the line and pushing it down a bit will help.
Running out at 1/4 tank means the 'showerhead' on the fuel send broke off. Its a plastic part that goes from the metal line to sit at the bottom of the tank with a coarse filter. You can find replacements, or use a short piece of rubber hose to get to the bottom of the tank. I have that on both tanks, with a T on the bottom of the hose, was cheap and quick. If you drop the tank to do that, try and get all the plastic piece from the showerhead out so they don't get sucked up and block the line.
Running out at 1/4 tank means the 'showerhead' on the fuel send broke off. Its a plastic part that goes from the metal line to sit at the bottom of the tank with a coarse filter. You can find replacements, or use a short piece of rubber hose to get to the bottom of the tank. I have that on both tanks, with a T on the bottom of the hose, was cheap and quick. If you drop the tank to do that, try and get all the plastic piece from the showerhead out so they don't get sucked up and block the line.
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7th Gear
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I got the switch off. One of the clips broke. I believe when I parked the truck that both tanks were full. I got the fuel out of the first tank by siphoning. I can't repeat the process on the rear tank although I did get 4 gallons out. I think maybe the hose I got in there was positioned in a bad place. That tank has some guard in place in the neck of the tank. I assume it is to prevent siphoning?
hen I disconnected the fuel line from the rear tank to the switch, the fuel started coming out. I thought it might be siphoning on its own. The truck is parked on a slight slope. I setup a way to catch the fuel and to allow it to continue siphoning. But it stopped after about 1 gallon. So now I have to figure that out.
Does the fuel sender signal pass through the tank switch? Because the front tank shows empty (which it is), but when I switch it to rear tank the gauge moves a little but still on the E. I know the rear tank is almost full.
Anyway I need to get the fuel out of the rear tank. Not sure how I will do that yet.
Thanks for all your help so far.
hen I disconnected the fuel line from the rear tank to the switch, the fuel started coming out. I thought it might be siphoning on its own. The truck is parked on a slight slope. I setup a way to catch the fuel and to allow it to continue siphoning. But it stopped after about 1 gallon. So now I have to figure that out.
Does the fuel sender signal pass through the tank switch? Because the front tank shows empty (which it is), but when I switch it to rear tank the gauge moves a little but still on the E. I know the rear tank is almost full.
Anyway I need to get the fuel out of the rear tank. Not sure how I will do that yet.
Thanks for all your help so far.
Last edited by gironha; May 23, 2025 at 12:12 AM. Reason: typo
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From: Western Mass
Yes the fuel sender signal goes through the tank switch. Yes it will siphon out if the rear is higher, I found that out a few weeks back when I wasn't expecting it and made a good mess of myself.... 
If you have a decent floor jack (or better yet a transmission jack), you can use it to drop the tanks even if they have a good amount of fuel in them. Attaching a board to the floor jack to make a bigger shelf for the tank to sit on would help.
If you have a decent floor jack (or better yet a transmission jack), you can use it to drop the tanks even if they have a good amount of fuel in them. Attaching a board to the floor jack to make a bigger shelf for the tank to sit on would help.
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From: Edmond, OK
Be aware that dropping the tanks is a MAJOR PITA! I had quite a bit of difficulty reinstalling the side fuel tank when I dropped it.
You should be able to lower the tank on the straps and fish out the fuel sending unit without dropping the tank completely (at least the side tank).
You should be able to lower the tank on the straps and fish out the fuel sending unit without dropping the tank completely (at least the side tank).
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7th Gear
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Just an update. I got the rear tank dropped. Yes it was a pain. I am still deciding if I want to replace with rubber. I think I will do so. I looked at the o-rings inside the ends. That looks like a major pain as well to replace them.
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From: Edmond, OK
Replacing the OE nylon fuel lines can be done, but you need; at least, a heat gun to fabricate them.
Here's a good thread on fabricating new nylon fuel line.
https://www.ford-trucks.com/forums/1...-tank-efi.html
Here's a good thread on fabricating new nylon fuel line.
https://www.ford-trucks.com/forums/1...-tank-efi.html
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