1996 f250 7.3 powerstroke...fuel leak on top of engine - Ford Powerstroke Diesel Forum
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post #1 of 8 Old 11-01-2010, 06:38 PM Thread Starter
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1996 f250 7.3 powerstroke...fuel leak on top of engine

Hey guys , ive heard alot of people talk about the common fuel leak on top of the engine.... what is the most common cause?

is it usally the fuel pump? i bought a new fuel pump.... how hard is it to replace the fuel pump?

Do i need any special tools? can someone give me a quick rundown on how to do it?

Im very mechanically inclined , its just that i have never worked on diesel engines... any pointers would be great

Thanks in advance!
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post #2 of 8 Old 11-01-2010, 07:00 PM
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Typical fuel leaks come from the short fuel lines connecting the fuel bowl (among others im sure). Replacing the fuel pump isnt bad- time consuming at worst. Remove the fuel bowl (definitly replace these fuel lines while doing it) and lines running to the pump. Theres a banjo bolt on the back of the pump that needs to be taken off to release to line fitting. The worst part is getting it out now. Because its mechanical you have to have somebody get a ratchet on your crank and slowly turn the motor over while you wiggle the pump. eventually the timing "piece", lol not sure what to call it, will push the pump up and out of the block enough to release it. Be careful not to break the bottom of the pump off. I did just that and was lucky enough to get it out easily with a magnet, but I dont think thats common. Good luck

1997 CC SB. Stage 1s, 17*hpop, S&B CAI. 4" straight pipe, TW tunes, zf5 swap
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post #3 of 8 Old 11-04-2010, 07:41 PM
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Quote:
Originally Posted by big_daddy234 View Post
Hey guys , ive heard alot of people talk about the common fuel leak on top of the engine.... what is the most common cause?

is it usally the fuel pump? i bought a new fuel pump.... how hard is it to replace the fuel pump?

Do i need any special tools? can someone give me a quick rundown on how to do it?

Im very mechanically inclined , its just that i have never worked on diesel engines... any pointers would be great

Thanks in advance!
the fuellines are 5/16 but im not sure. you will need a 1 1/4 wrench for the rear pump fitting, there re two bolts on the uel bowl(3/8 ot 7/16) also ned a 1/4 socket and racket with a 8'' extension, pull all the bolts on the fuel bowl and then all the fuel lines, get filter off the side and you can get to the bolts on the pump, break the line on the back off the pump before you lossen the bolts. then pop out the pump. you need to replaced all the rubber lines on the bowl and the pump. lube the o-ring on the pump before you put it in. put it all back and put on new clamps on the hoses, upon start up pull the top of your filter bowl and have someone crank on it till the bowl fills up and then put it back on and it sould start

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post #4 of 8 Old 11-29-2010, 01:36 PM
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how many hoses r their they like they r 1in long
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post #5 of 8 Old 11-29-2010, 01:37 PM
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also what size hose or should i go 2 the dealer n get them i have the same fuel leak 2 bad i cant put a inline pump
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post #6 of 8 Old 11-29-2010, 06:05 PM
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I wouldnt waste the money at a dealer. Theyre just typical fuel lines, nothing special. I would just head to auto zone or whatever is local and buy a foot of 5/16" fuel line.

1997 CC SB. Stage 1s, 17*hpop, S&B CAI. 4" straight pipe, TW tunes, zf5 swap
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post #7 of 8 Old 11-29-2010, 07:58 PM
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I have a stupid question, how can you tell if it is the fuel pump that is leaking or just the hoses? Can you just replace the fuel lines and O-rings and solve leaking problem. Mine is leaking, but have not got under or on top to look at anything yet, maybe Wednesday if rain stops?

1996 F-250--Stock (at least for know )except for a 2 inch lift
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post #8 of 8 Old 12-01-2010, 11:39 AM
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Quote:
Originally Posted by kylev90 View Post
I wouldnt waste the money at a dealer. Theyre just typical fuel lines, nothing special. I would just head to auto zone or whatever is local and buy a foot of 5/16" fuel line.
Like everyone else is saying, don't waste the money at the dealer, go to a parts store and get fuel line for diesel use. The lines attached directly to the pump are not 5/16" like everyone else is saying, they are 3/8", the other lines on the fuel bowl are 5/16". Buy a foot of 3/8" and 6" of 5/16" and you will have a little extra left over still. I've replaced the lines and fuel pump on 2 trucks in the last 3 months.

Also the bolts on the fuel bowl are 13mm and 10mm, not 3/8" and 7/16". The rear banjo bolt on the fuel pump is 1 1/4" or 32mm which ever you have access to will work.

Here is a good link to read with all the info you will need to replace the fuel pump:fuel pump - Diesel Forum - TheDieselStop.com

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