What's a fuel return and why do I need one? I just read somewhere in here that one is the first mods you should make to a 7.3 is a fuel return. What is that and what does it do for me?

 

I believe you are referring to extending the return line in the fuel tank. This is part of the prepump in-tank mods that removes the mixing chamber and moves the exit of the return line away from the suction screen. This prevents bubbles from the returning fuel to be sucked up and sent back to the engine. Most buy a kit that has everything included to do this mod. Here is a link that will help explain it better: http://www.itpdiesel.com/other/FuelS...Kit-Manual.pdf

 

Stock 7.3's have a fuel return line that allows excess fuel not needed in combustion to return to the fuel tank.

The modification I think you are talking about addresses a couple of problems with the delivery of fuel to the injectors. The problem most often described is the uneven amount of fuel delivered to the number eight cylinder due to the design of the fuel rail and the firing order of the cylinders. The design of the fuel rail means that the fuel "dead ends" at the end of the 2 fuel rails. It seems the #8 injector in particular is starved of fuel resulting in premature wear of the injector, some power loss and increased noise often referred to as cackle. Another sympton of the "dead end" fuel rail is there is no way for air in the fuel to escape and this aggrevates the fuel starvation. The simplest mod is to remove the dead end of the fuel rail by allowing fuel to flow out the end of the two rails through the addition of new fuel hoses that connect to the existing fuel return to the fuel tank. The result is a more balanced fuel supply to all cylinders, air is allowed to escape the fuel rail through the modified return to the fuel tank and the engine runs more smoothly and quieter.

The mod is sometimes referred as a Cackle Cure and while there are probably a few suppliers of the kit to do the mod, the one I know of is from Dino Fuels Alternatives (A FTE sponsor)and is listed in their products section as a Crossover Kit. Check it out at vegistroke.com

There are more complicated and expensive modifications that are described as Regulated Fuel Return systems that deal with the deadhead fuel rails and provide a better fuel supply. A number of suppliers have some form of this mod.

People who have reported on doing on the Cackle Cure kit also seem to add a High Pressure Crossover fuel line to equalize pressure between the two fuel rails.

Hopefully some one else will provide more details or description of the modification and the benefits.

 

That was a well though out description of the CCK.

[Quote] People who have reported on doing on the Cackle Cure kit also seem to add a High Pressure Crossover fuel line to equalize pressure between the two fuel rails.[Quote]

I think you are referring to the HPX crossover to equalize the oil rails. Which is simular but for oil and simple to install.

 

Jason

You are right about the High Pressure Oil crossover line that goes between the two Oil Lines.

Glenn

 

Thanks for the replies guys, sounds like a lot of trouble for not much return though. Am I right in assuming that the fuel lines are run inside the valve cover? I know where they were on my fuel injected Dodge (yuck) but haven't seen them on my 7.3.

 

Shade

Check out the following thread on the Cackle Kit from an earlier post in this forum from F250_ It has a lot of information and discussion about the Cackle kut


https://www.ford-trucks.com/forums/59...s-the-job.html

An evaluation of the kit is available at
Powerstroke Mods and Maintenance in the Cackle Kit Cure - Test results

There are pictures in the installation instructions at the end of the evaluation link from the thread. The install instructions details what is involved to make the connections to the fuel rails and to splice into the return fuel line.