This has been addressed previously and was a recall but mine is passed that time. The front fuel pump (fuel delivery module) does not work at all (engine won't run). I run the truck exclusively from the rear tank. I want to tee off the return line to the front tank into the line to the rear tank, bypassing the front tank entirely. My question is how much pressure is on these return lines? Can I use barbed fittings and clamps or do I need to use higher pressure fittings to prevent leaks?

 

what engine in my 302 the psi for fuel pressure is 45 at most stock if within spec so the fitting would mostly have to be able to handle 45 at most

 

I used barbed fitting and clamps on my fuel line and havent had a leak in 3 months after doing it...

 

You'd need to pinch off or cap the front supply line, the problem is the fuel is back feed to the front tank from the rear tank by the "supply" not the "return".

Simply rerouteing the return will not correct the problem.

Why not just replace the front pump/sending unit?

 

I have considered replacing the front pump but I'm a cheapskate. The repair manual said the front tank would overfill by way of the return line if the check valve in the front pump assembly failed. I hadn't thought about fuel reaching the front tank by way of the supply line. Thank you for your reply. I'll likely buy the pump and be done with it. It's a 302 FI.