I have a fuel leak on my 2003 F-250. I can see the leak. It is coming from the junction where the fuel line changes from a flexible line to a hard steel line under the motor on the drivers side. The steel line goes up from there up to the fuel bowl. I haven't taken anything apart yet. My question is what needs to be fixed. Is there an o ring in this junction that can be changed? Do I need to replace the entire flexible line? I'm not sure which line it is as there are two lines there. I assume one is a supply and one is a return line. Any suggestions?

Pete

 

Sounds to me like it will probably require a new line. Most of the time if it goes from a soft line to a steel line that connection can't be fixed (but I could be wrong). If you post a pic, somone can probably tell you which line it is.

 

Pete

There are 2 fuel lines, the supply and the return line. On my truck the supply line is 5/8" and the return in 1/2". The smaller line is closest to the outside of the truck.

See attached picture of the steel fuel ines.

Could be the soft fuel line leaking but the reason I have the part in the picture is I have a small hole in the steel supply line that needs fixing on my truck.

Glenn

 

Doubleubar
That looks like the problem area. I stopped by the Ford dealership today and they said that supply/return hose assembly has a complete unit from the tank to the fuel bowl which would include the flexible and hard lines. From your picture it looks like you just have the hard steel lines only. Mine are rusty and it's hard to tell exactly where the leak is from. It looks like it is coming from the connection between the flexible and hard line. If you can replace the hard line only how do you open up the connection. Did you buy that hard line at the dealer? If so do you have a part number ?

Pete

 

Here's the diagram

 

Parts list cont'd
Item Part Number Description
1 445684 Plug 1/8 Pipe
2 1820516C1 Stud Bolt
3 299400C1 Clamp Wrap
4 1826714C2 Fitting (One-Way Flow)
5 1830970C91 Fuel Delivery Line (Right Cylinder Head)
6 606885C1 Fitting (2 Req'd)
7 1830969C91 Fuel Delivery Line (Left Cylinder Head)
8 1831211C1 O-Ring
9 1831190C1 Fuel Heater Thermostat/Water Sensor
10 1831208C1 Screw (2 Req'd)
11 1831212C1 O-Ring
12 9324 Hose
13 1831398C1 O-Ring
14 1831187C1 Fuel Regulator Cap
15 1831209C11 Screw (2 Req'd)
16 1825389C91 Fuel Return Line
17 1825389C91 Fuel Supply Line
18 9R551 Screw
19 299402C1 Clamp Wrap
20 1817812C1 Screw
21 — O-Ring
(Part of 1825956C1)
22 9L273 Water Drain Tube
23 9G524 Oil Deflector
24 9F593 Fuel Injector
25 — Backup O-Ring
(Part of 9E527)
26 — Cushion Ring
(Part of 9E527)
27 — Fuel Injector Middle Seal
(Part of 9E527)
28 — Fuel Injector Lower Seal
(Part of 9E527)
29 — Fuel Injector Gasket (Copper) (Part of 9E527)
30 1822607C91 Pipe Plug
31 — O-Ring
(Part of 1822607C91)
32 — O-Ring
(Part of 1807329C91)
33 1851329C91 Oil Pressure Sensor
34 1825956C1 Quick Connect Fitting
(4 Req'd)
35 1831130C1 High-Pressure Oil Lines
36 — O-Ring (Part of Kit)
37 9417 High-Pressure Oil Pump Flange Gasket
38 9A543 High-Pressure Oil Pump Assy
39 9L968 Injection Pressure Regulator
40 9155 Fuel Filter

 

Hi Kirkharrod

I don't see a diagram

Pete

 

Pete

I purchased the steel lines as a single item from a ford dealer. The part number is F81Z - 9J338 - NA. It was an expensive part - Over $200 Cdn. I think you are getting bogus advice from the dealership.

I would suggest you make sure the leak is not from the soft line before you order the steel lines. Probably a lot cheaper fix. You may be able to use non Ford fuel lines with clamps to replace the soft line. It would need to be diesel rated fuel hose.

The connections are opened up using a small plastic tool that slide over the line and when pushed against the connection releases the "quick"connector of the soft line. Looks like these. Inexpensive and available at most parts stores



If you need the steel lines, check with Parts Guy Ed who is active on this forum as he would give you the an option of not having to go to the dealership.

Glenn

 

F81Z9J338NA list for $131.37 sell price $check my web site

 

I ordered the assembly from PartsGuy. My steel lines are very very rusty. When I replace this part is there anything I can do to prevent having all the diesel drain out of the tank?

Pete

 

does anybody at all know how to remove these two lines ? what all will i have to remove on the front of the motor to get them out if anything ? any help will be greatly appreciated