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Howdy, y'all. I've had this truck approx 5 months and had to replace the fuel return line 4 times. Longest stretch without issues is 3 months. The first 3 times were cracks in fittings. Fastest failure (most recent) is same day and under 15 miles traveled which is in the attached pics. I'm just looking for the most likely culprit. Just FYI, when I bought it from the dealership it had approx 134k miles, DPF/EGR delete, CCV delete, and DCR conversion. Codes have been tuned out but no idea about additional tunes. The dealership said they were unable to contact the previous owner to ask about obtaining the tuner or ask about tune settings.
I've taken it to a shop to be replaced. I believe the first couple were from NAPA but this last one came from a Ford dealership. This things has been screwy. The initial break was about 3-4 weeks after I bought it. That replacement line lasted almost 2 weeks. Then, 3 months til this last issue! I picked it up last Friday and that dealer provided line didn't last 15 miles before the hose came off that fitting. I put a zip tie on it to get it back home and it still blew off a couple times. I kept trying to tighten it more each time.
I have seen this a couple of times and you are not going to like my experience.
This is 90% a restriction in the fuel return line -or- a 10% defective injector dropping high pressure fuel to the return line.
The 90% is 100% due to DEF in the fuel which crystalizes and clogs the return fuel line. Some shops, in an attempt to save the customer some money will not replace the fuel return lines to the tank.
I have seen this a couple of times and you are not going to like my experience.
This is 90% a restriction in the fuel return line -or- a 10% defective injector dropping high pressure fuel to the return line.
The 90% is 100% due to DEF in the fuel which crystalizes and clogs the return fuel line. Some shops, in an attempt to save the customer some money will not replace the fuel return lines to the tank.
I've seen a few comments on other threads that mention DEF mixing with fuel. I just don't see that as a highly likely scenario. I haven't put DEF in it because of the prior mods. It ran fine for the initial 3-4 weeks. The first replacement did crap out quick but then a 3 month ride before it took the next dump. Obviously I'm no mechanic. The shop I took it to said they checked the return to tank line and it didn't appear to have any obstruction. What method they used, idk. How hard is it to replace that line? How could I check it to examine it myself?
