Fuel line broken, need help figuring out repair/replacement...

[Peter Griffin]

I posted this in my build thread but thought it'd be a good idea to post it up to get some more eyes on it and hopefully some help...

UGH!

While changing out the valve cover gaskets today the fuel hose on the right next to the regular (which originate on the output side of the fuel filter) got disconnected. No big deal, I re-clip it on prior to a test fire. As soon as I do I can see (and smell) fuel leaking from it. I kill the motor and take a look at it and the rubber hose is actually an outer and there's a smaller/hard plastic inner hose. I tried a traditional hose clamp and that wasn't working so I'm trying to figure out how I'm gonna fix it...replace the whole line, cut and splice in a repair...suggestions?

I did re-pull the valve cover off out an abundance of caution to make sure that nothing fell off the line the fuel line and into the valvetrain and a pretty length inspection I'm almost certain that did NOT happen but I wanted to make sure anyway.

So two steps forward and one step back. I'm gonna be all out of sorts until I get this mess straightened out!

 

[mikkelstuff]

I absolutely hate that Ford plastic fuel line. I replaced all I could reach on my 2002 Ranger with rubber fuel injection system hose.

 

[Peter Griffin]

Is it 3/8ths or 5/16ths if anyone knows....?

 

[RonD]

All Rangers use 5/16" nylon fuel line, but....................they use both 5/16" and 3/8" fittings depending on where it is
i.e. fuel lines on tank will be 3/8" fitting for Pump, and 5/16" fitting for Return, so they don't get mixed up

Dorman sells Ford connectors and hose repair stuff
Nylon line can be spliced its just a pain
You need to heat it up to get it pliable so you can push a fitting into it, when it cools is super tight so no clamps needed

Google: repairing nylon fuel line

 

[Peter Griffin]

Thanks for the informative reply @RonD I appreciate it!

 

[Peter Griffin]

MAN did I WAY overthink this...I should have known better. Whenever you guys are ready to nominate the TRS Drama Queen of the Year don't forget this thread!

I used my fuel injection/A-C line removal tool to get the fitting off of the fuel rail and after 35 years it was not in a mood. I had to push the line in to seat it as firmly as possible while pushing the tool in to unlock it. It still wasn't coming out but I noticed some play in it and grabbed the channel locks and started pulling on the barbed inlet which was covered by the broken fuel line so I wasn't worried about boogering it up. With a firm pull it came out so I could finally get started on my repair...

Ended up using a small section of high pressure fuel injection line, slid that over the barbed input end and then used a double-ended splicer to join those two together. It ain't purdy but it works and it fired right up and ran just fine, no leaks...WHEW!

 

[RobbieD]

Whenever you guys are ready to nominate the TRS Drama Queen of the Year don't forget this thread!

My vote is in.

You're getting there; the more it fights you, the better it will turn out when you're done.

Carry on!

 

[Peter Griffin]

I'm in NO rush to get it done and it's been a great learning experience, especially with all y'all here helping me out along the way, I appreciate it and the TRS has been an invaluable resource among others in getting me through stuff when I hadn't a clue!