Broken return fuel line - Ford Powerstroke Diesel Forum
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Old 04-05-2013, 04:14 AM
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Broken return fuel line

I want to start by thanks for all the help over the years. I can rely on this site to help me with my F250 but now it is time to give back.
Last week I was at the store and cranked my truck and as I was loading the truck with grocerys I was smelling diesel. I looked under it and diesel was all over the ground. When I got the truck home and in the shop I can see diesel dripping down under the turbo (that not good). After looking closer I noticed that it was the return line on the passenger side of the truck. The clamp that holds the metal line from moving around rubbed a hole in the line. When I got the new line from ford the parts guy told me how they fix the problem and I wanted to share with everybody on here.
1. Take the metal clamp and throw in the garbage.
2. Buy 3/8" fuel or vacuum hose about 3' and small zip ties from auto parts store.
3. Split it all the way down like a hot dog bun.
4. Wrap the new line and zip tie about every 1 to 2 inches.
This was a very easy thing to do to protect the fuel line for future problem.I think the hardest thing was getting the fuel line off the back of the head I had to cut a 9/16" wrench to get it in there and get my 15 year old daughter off the phone long enough to get her little hands in there to remove and install the lines.
Here are some pictures I took.
Attached Thumbnails
Broken return fuel line-fuel-line-001.jpg   Broken return fuel line-fuel-line-002.jpg   Broken return fuel line-fuel-line-003.jpg   Broken return fuel line-fuel-line-004.jpg   Broken return fuel line-fuel-line-005.jpg  

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Old 04-05-2013, 06:31 AM
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yup, but i would've re-used the "P" clamp, to keep the new fuel line from vibrating all over the place. You can just use a small piece of vinyl tubing or whatever, stuff it around the line where the clamp is, then reclamp it over the fuel line.
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