I have a 97 F350 7.3L. I replaced to the fuel pump a couple of times over the last 2 years. I have noticed that when it gets cold, I have a fuel leak, Oring shrinkage maybe. Anyway, Can I bypass the fuel pump relay to pressure the system without the truck running? If so, where is the relay? I am on my way to the ford house for the Oring kit and Hose kit. I need help really bad, getting @#%& tired of the fuel leak. Any help would be greatly appreciated.

 

Can you see exactly where its coming from? If not, take the cover lid off and try to dry everything off by sticking rags down in the valley. Start the truck. Then use a bright light to find the leak. We need to know exactly where the leak is coming from. It could be alot of different places.

 

That's my problem. I don't know exactly where the leak is coming from. I was told that you could bypass the fuel pump relay, so the fuel pump will pressurize without the truck running, that way I could crawl around on the top of the motor without the fear of getting caught up in the fan or belt. If anyone knows how to do this, please let me know.

 

I could be WAY WRONG and before you try what I am about to say, lets hear what others think about this............Could you get an air tank w/50PSI or so in it and apply it to the Schrader valve on the FPR?

 

Good point! Safety first. I went on the passenger side over the fender to spot my leaks, not from the front. Yes, be very careful! no loose cloths. Shut the motor down before you do any work.

 

Unless your in the wrong forum your truck has a mechanical pump not electric..

 

I think all (and I could be wrong) that all fuel pumps on the diesels are mechanical, even on the 09'ns. But it could have been modded somewhere along the line.
Yo slick is right (if we are on the same sheet of music), there is no fuel pump relay

 

Check the fuel pressure at the Schrader valve at the FPR. If it is too high, it can cause the fuel pump to fail early. I think 85PSI is the max.
If you have a Cali model, it should be about 75PSI stock. If you mod it with a BB (by experience) it will be to high and cause the fuel pump to fail prematurely. Just something to think about. How many miles do you have? What kind of modifications do you have? How long have you owned the vehicle? What kind of problems have you had with it prior to this one?

 

Here is the history of my truck, since I have owned it. It is a 97 F350 CC 4X4. Has an E4OD tranny. It has roughly 180k miles. I have replaced waterpump, vaccume pump (x2), starter, and fuel pump X2, removed bad water/ fuel sensor. I replaced the fuel pump the second time because it started leaking again. Thought maybe I got a bad pump, turns out I forgot banjo washers. Put new washers in, fixed the leak for a while. A couple of weeks ago, noticed it was leaking again. Pulled the pump and filter housing. Replaced all of the hoses again. Put everything together prior to putting back in truck, and tightened all of the clamps. Now, I still have a leak.

Does anyone know if there is a way to pressurize the fuel system without starting the truck? I doubt it, but it is worth a shot. How else can I locate the leak? This has been going on for about 2 years now, since the first sign of a leak.

 

Also, I went to the ford house today for an Oring kit and Hose kit. They said that I couldn't get the Oring kit without the entire drain assembly. And the hoses had to be bought seperately. I thought that I read on here somewhere that you could get an Oring Kit and Hose kit. Is this true?

 

I wonder if the Banjo bolt needs some more snugging? I would maybe drive it and get it up to operating temperature and maybe putting some air to the Shcrader vale (ONLY IF RECOMMENDED BY OTHERS ON HERE) and check it. OR just snug the Banjo bolt up.
It even could be the fuel bowl lever is stuck open some (last time I used mune it was a booger to shut off). I would also make sure the fuel pressure @ the FPR isn't too high.

 

It has been my experience Ford will bend you over the barrel and have their way with you dry with no lube! Do you have a International dealer near you?

What ever the problem is we will help you straighten it out.

 

I had to buy the hoses separatly. they are blue and suppose to be heat resistant. It could be the ends of the banjo fitting. If you dryed the valley with rags. and took a trouble light or bright flash light you could see down their. start the truck and run it for a short time then shut it off and look in the valley agian to see where it's coming from then you would not put yourself in danger. Is the leak in front of the fuel pump or behind it. If it's behind the fuel pump it is either the vent hole in the fuel pump ( not likely because you just changed it) or the banjo fitting, or the ends of the banjo fittings . The O-ring on the bottom of the pump would leak oil not fuel. If you still can't see Where the leak is coming from Start the truck again and rev it up Shut it off and Check again. Other wise your just guessing and replacing parts and spending money. It took me a while to find my leak. Mine was coming from the fuel pump vent hole on the bottom of the pump.I don't think that's your problem. The dealer told me to give up because it could be coming from anywhere and i would drive myself crazy tring to find it. I didn't listen and now my truck doesn't leak fuel or oil!

 

I will look at it tomorrow and see what I can find. I will keep everyone updated

 

Are you using SAE30r9 hose? A leak that occurs with temp changes says hose issue. O ring kits are available from diesel o-rings or NAS automotive. NAS also has a kit with correct hoses. Take apart your bowl and FPR. Clean it up good and install new o rings and reassemble. Put a 1/8" NPT plug where the fuel pressure sensor is. Inspect the return hoses to the FPR. By this time I would have gone electric. I'm looking forward to doing a pump change soon too. I'll do it once because I'm doing some testing. But after thats done. Electric all the way.