In-Tank Mod Help!!!!????
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Senior User
Joined: Jun 2010
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From: Washington
In-Tank Mod Help!!!!????
Ok guys in doin the DI in-tank mod. Im just at the point where you drop the tank and i've got everything disconnected and the tank lowered part way but im not sure how to disconnect the fuel lines. I have an 03 PSD shortbed, and in the directions it says to cutt the fuel line at the rail. My question is there are two lines comin from the sending unit? Do I cutt both? The kit comes with two extra lines but I think one is for the fuel filter part cause its shorter and narrowers than the other? So what do I need to do?
Any help ASAP would be great thanks!
Any help ASAP would be great thanks!
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Joined: May 2010
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From: Weldona, CO
You need a disconnect tool. It is a small (usually plastic for the cheap ones) that is inserted into the quick disconnect fitting and will release the line. You can get them at any auto parts store.
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Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzleguzzle's Mods & Maintenance website
Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzle
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From: Washington
Ok. In the directions it says you only need the tool for the 00 and 01. Mine is an 03 and they seem to be crimped on!? Thats where the directions say to cut it off?
So I just need to make sure before I get the tool and it doesnt help my situation.
Thanks for the reply.
So I just need to make sure before I get the tool and it doesnt help my situation.
Thanks for the reply.
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Joined: May 2010
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From: Weldona, CO
Mine was an 02 and I had the tool to use on the tank. It's been so long now that I don't remember if I had to cut one off or not but I do remember that I had a quick connect on at least one of the lines to the tank plus the other quick connects on the frame.
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Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzleguzzle's Mods & Maintenance website
Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzle
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From: South Carolina
<TABLE cellPadding=5 width="90%"><TBODY><TR><TD width="20%" align=left>
</TD><TD align=left>From Guzzle"s site.
Welcome to guzzle's In-tank Hutch Mod Web Page
There are 4 bolts holding the tank to the frame. Support the tank at both ends, not in the middle where the fuel pickup is located and unbolt the strap anchors. Remove the straps and lower the front end of the tank enough to reach the fuel lines at the pickup cover. Disconnect the front tank vent tube. This vent tube goes through the bed frame support and connects to the rear vent connection. The rear connection will be disconnected later. With the vent tube moved out of the way, you will have enough room to unplug the electrical sender connector. Use a fuel line disconnect tool to open the vibrolock connectors on both the 3/8 and 5/16 lines on the tank. Lower the rear of the tank enough to disconnect the rear vent line.
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I think you are looking at the vibrolock connectors. They do open with a fuel injection line tool.
</TD></TR></TBODY></TABLE>
)
</TD><TD align=left>From Guzzle"s site.Welcome to guzzle's In-tank Hutch Mod Web Page
There are 4 bolts holding the tank to the frame. Support the tank at both ends, not in the middle where the fuel pickup is located and unbolt the strap anchors. Remove the straps and lower the front end of the tank enough to reach the fuel lines at the pickup cover. Disconnect the front tank vent tube. This vent tube goes through the bed frame support and connects to the rear vent connection. The rear connection will be disconnected later. With the vent tube moved out of the way, you will have enough room to unplug the electrical sender connector. Use a fuel line disconnect tool to open the vibrolock connectors on both the 3/8 and 5/16 lines on the tank. Lower the rear of the tank enough to disconnect the rear vent line.
</TD></TR><TR><TD colSpan=2></TD></TR><TR><TD width="20%" align=left></TD><TD align=left>
I think you are looking at the vibrolock connectors. They do open with a fuel injection line tool.
</TD></TR></TBODY></TABLE>
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From: Washington
Ok. I finally figured it out. Kinda feel like an idiot, but ya got make mistakes to learn sometimes!
Anyways the connectors on the sending unit have a small button on the outer ring that I pushed with a screw driver and what do ya know they popped rite off, no cutting required!
On with the process!............
Anyways the connectors on the sending unit have a small button on the outer ring that I pushed with a screw driver and what do ya know they popped rite off, no cutting required!On with the process!............
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From: Washington
Next problem. Is there a trick I can use to get the new stainless tube into the pickup foot?
I drilled the foot out with a 3/8" bit but its still bein a PITA to get in. Should I drill it out larger? I know it needs to be tight but I cant even get it all the way past the check valve, and I want to be able to put it in and take it out cause im pretty sure I will have to cut it down cause my measurment is 13 3/4" from top to bottom.
Thanks.
I drilled the foot out with a 3/8" bit but its still bein a PITA to get in. Should I drill it out larger? I know it needs to be tight but I cant even get it all the way past the check valve, and I want to be able to put it in and take it out cause im pretty sure I will have to cut it down cause my measurment is 13 3/4" from top to bottom.
Thanks.
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Joined: May 2010
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From: Weldona, CO
Just keep working with the drill bit but be careful not to get it in a bind as the foot can easily crack. Just use a drill bit and a pair of pliers to turn it. It takes a while but it is the safest.
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Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzleguzzle's Mods & Maintenance website
Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzle
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From: Tampa, FL
Next problem. Is there a trick I can use to get the new stainless tube into the pickup foot?
I drilled the foot out with a 3/8" bit but its still bein a PITA to get in. Should I drill it out larger? I know it needs to be tight but I cant even get it all the way past the check valve, and I want to be able to put it in and take it out cause im pretty sure I will have to cut it down cause my measurment is 13 3/4" from top to bottom.
Thanks.
I drilled the foot out with a 3/8" bit but its still bein a PITA to get in. Should I drill it out larger? I know it needs to be tight but I cant even get it all the way past the check valve, and I want to be able to put it in and take it out cause im pretty sure I will have to cut it down cause my measurment is 13 3/4" from top to bottom.
Thanks.
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From: Washington
Finaly was able to get it here a few hours ago. Just used the drill bit and worked with it and it finaly went all the way in. Got the sending unit all put back together and ready to install back in the tank.
My tank has quite a bit of crud in the bottom so now I have empty the tank of the last few gallons of diesel to get all the crud out, then I can reinstall the sending unit and tank. And install the pre-pump filter.
One last question before reinstall though, has anyone ever used any sort of glue on the pickup foot screen to keep it in place? Just wonderin cause it seems like it may be able to slide out over time?
Had to go to work so hopefully I can get it back on the road in the next day or so! Thanks for all the help!
My tank has quite a bit of crud in the bottom so now I have empty the tank of the last few gallons of diesel to get all the crud out, then I can reinstall the sending unit and tank. And install the pre-pump filter.
One last question before reinstall though, has anyone ever used any sort of glue on the pickup foot screen to keep it in place? Just wonderin cause it seems like it may be able to slide out over time?
Had to go to work so hopefully I can get it back on the road in the next day or so! Thanks for all the help!
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From: Tampa, FL
Im not sure glue would hold up. I don't know the effects diesel has on glue but I know gas will break it down. Anway since you're in the tank and gonna clean it out cut the fill and vent tubes. If you cut them as short as possible you will get more fuel in there in a fill up. I did it and my tank went from something like 27 to 34 gallons before the pump clicks off. Such a beaut! lol
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Done..........for now! I've got everything done and the tank back in the truck. Just gotta go get some diesel and see how she runs.
After I finished I decided to inspect the old filter/mixing chamber thing from out of the tank. After I tore it open I discovered that it was empty, as far as filters or screens go.
There was no screens in the mix chamber at all, I thought that there was supose to be screens in there? Am I missing something?
After I finished I decided to inspect the old filter/mixing chamber thing from out of the tank. After I tore it open I discovered that it was empty, as far as filters or screens go.
There was no screens in the mix chamber at all, I thought that there was supose to be screens in there? Am I missing something?
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Joined: May 2010
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From: Weldona, CO
Looks like someone got to it before you did..... With no screens and no pre-pump filter, I would pull the pump and see how much crud is stuck in the pump inlet screen before doing too much test driving.
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Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzleguzzle's Mods & Maintenance website
Specializing in Viton® o-rings and leak repair kits for the 7.3L and 6.0L diesels
(970) 368-4455 aka guzzle
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Senior User
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From: Washington
But checkin the pump sounds like a plan! Though I did drive it already, just to work and back about 20 miles. Ran great but on the way back I got it to about 85 or so and it started to do the same thing, just slightly. Backed of to 70 and all was good.
So could this be the pump bein clogged or HPOP not keepin up?? Seems to me like the pump bein clogged would cause this when its in need of alot of fuel.
Thanks again for all the help. Cant wait to get her to 100%
Anyways ill check it out tomorrow. Anything I should be aware of when takin the pump out? How do I get to the screen?