DFA Cross Connect Kit on an early 99

[samiam]

i found a few other threads about install and use of the Dino Fuel Alternatives Cross Connect Kit, but nothing in the early 99 forum. I am towards the end of what should have been a couple hours install by myself. I'm wondering if the different turbo on the early 99 is causing my pain. i'm guessing the diff size turbo is causing a tighter tolerance for getting the driver side fuel rail plug out, and getting the pipe fitting in so i can connect the fuel hose. i'm guessing that in later 99's there's more space right at that critical point and they didn't take it into account when marketing this to all 99's.
Does anyone else know what i'm talking about? actually it was easy removing the square-top fuel rail plug, it's just getting the fitting into the hole that's a royal pain.
the only thing i can think of is to disconnect the collector from the back of the turbo and push back the up pipes enough to get the bolt in. it only has to move back by about an 1/8".
the tolerance is so tight i can't rotate the fitting to screw it in, since the squared edges of the fitting hit right at the joint of the collector and up-pipe. once the fitting is in place i'm sure the up-pipe will fit back into place, it's just too tight to actually spin the fitting to screw it in.
allright, so, how hard is it to get that collector free from the back of the turbo? i loosened the nut on the v-clamp, but it's not very easy to get off, i don't want to break it, and i'm worried about creating even more of a PIA situation if i remove it.
thanks. and please excuse me if i did a hatchet job on the verbage and terms here.
anyone have any other thoughts for a proper homemade connector at this point? i know i can screw a 1/8" MIP fitting with a male barbed fitting into the hole, and just push the fuel hose down onto it, but that would actually cause contact between the fuel hose and the up pipe for about a 2" length. I don't know the specs for fuel line hose, but it sounds like that would be too much heat on the hose.

[cvdenson]

Yes I know exactly what your talking about. I have the ITP regulated return and I had to grind away some of the up pipe collector to get the fitting in, per instructions. I used a dremmel tool to get my clearance. Once I did this, it fit perfect.

Chris

[samiam]

I went to a shop this morning that specializes in connectors and hoses. called Fluid Connector Products, if anyone cares to know. they made me a short piece of hose with the correct fittings on the end. much smaller piece to screw into that fuel hole. the hose is teflon so it's good for diesel fuel. hose is wrapped in a woven steel and fabric sheath and is heat resistant up to 450 degrees, and it's a slightly smaller diameter than the rubber fuel hose. got the connector on the other end with a barb fitting so i can cut off the DFA hose fitting (90 elbow) and push the barb straight in. i'm hopeful that this is the solution. cost $14. they gave me the 8 inch piece of hose free.
that's a good idea about the dremmel, though.

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Last edited by samiam : 10-15-2008 at 02:23 PM.

[samiam]

I wrote an email to (name removed) at Dino Fuel Alternatives. Here's what I wrote:
"I am certain that the early 1999 model Ford diesel Superduties (F-250/350) need different instructions and parts included for the CCK. I have talked to a few early 1999 owners in the past 48 hours and they've had the same experience I have when installing a cross connect kit (from any manufacturer). An early 1999 is defined as being manufactured prior to 12/98, generally. The turbo and collector and up-pipe is different than later 99-03 models. this causes a restriction on access to the fuel plug on the drivers side head. there's no room to install your NPT fitting and hose, unless you remove the up-pipe or grind into the up-pipe. I had to have a shop fabricate me a short length of high heat resistant (steel braided sheath) fuel line and a fitting to get into the fuel port. it cost me $15, not to mention the time trying like crazy to make that NPT fitting and hose connect supplied with the CCK fit, and a few trips to the hardware store trying to fabricate my own part, before giving up. thought you should know. of course i'll feel silly if you tell me you're aware of that and that you have a part available."

I won't post the actual reply, but I'll paraphrase. PM me if you'd like to get his actual reply verbatim. He said "I hate to burst your bubble, but i am fully aware of the Early 99 differences.... the trick is taking a dremel... clearancing the exhaust flange... not any special fittings for that since the clearance is so tight... I will try to get the instructions modified."

So there you have it. The CCK is well-constructed as far as I know, i've only had it installed for about 12 hours and 20 miles, so too early to talk about improvements to my engine operation. The company is aware that the early 99 needs special attention but they don't offer any special parts to accomodate installation, and their marketing and instructions on the CCK don't mention anything at all.

I'm not putting this out here to warn off customers from DFA, i'm just warning unaware customers about the reality of installing the Cross Connect Kit.

By the way, the hose and fitting shop told me they were positive they could make the same hose and fitting (with special check valves) for about $65 bucks. DFA cost was $119.95. I coulda' woulda' shoulda' made my own, but I just wasn't confident before this that I could have.

Scott Brundidge

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Last edited by samiam : 10-16-2008 at 11:16 AM.

[Dirk]

Originally Posted by cvdenson

Yes I know exactly what your talking about. I have the ITP regulated return and I had to grind away some of the up pipe collector to get the fitting in, per instructions. I used a dremmel tool to get my clearance. Once I did this, it fit perfect.

Chris

I Might have helped you with this. I don't remember.

The early 99 will be the exact same as a late 99-03. Except for one BS piece... the driver side rear port. You have to grind off some of the y-pipe. The reason is the early 99 turbo mounted a bit more forward and lower to the engine.

[cvdenson]

You did Dirk way back when. FWIW Scott, before I got the ITP kit, I bought the DI regulated return and it called for clearancing the up pipe as well. I sent it back because I didn't care for the quality of the kit compared to Dennis's kit. I had a much easier time with the ITP kit.

Chris

[cvdenson]

I didn't notice a big difference in how my truck ran, maybe a little smoother. But my truck sits right now because its leaking coolant out the back of the passenger side head.

Chris

[Ron's power stroke]

i will not buy from them at all ether..I tried to email them for a little over month about his new RR kit...$700 set up by the way,.. I got sick of no return email and went with another vender..a month later with no response I posted on another forum and here was his reply

Quote:
Originally Posted by ron's power stroke
I have sent him 3 emails here and on his site about the RR kit with no answer...figured he didnt want to make a sale..I got a DI RR on its way now....

Ron- Got your email and that was on my short list for emails to return. But sounds like I don't need to worry about it now. Amazing the change when going from a basic gearhead to a business owner, Not to make excuses, but it is a whole different world. It is always a choice of how to use my time- And sometimes it boils down to helping existing customers, or helping potential customers, And of course we want to make sure that existing customers are helped first, then on to new customers that haven't given us their money yet. Sorry I couldn't get to you sooner....

if he cant return emails to a new customer that hasn't spent money yet cause he is too busy to answer questions for current customers who are most likely having problems (like you had with the CCK) and are not spending more $$..makes me wonder how long it would have taken to get my RR kit..it all worked out in the end..after some digging around found out the fass pump isnt all its cracked up to be..i went with the DI RR and the Walbro GSL-392 fuel pump instead.turned out to be a cheaper but better rout..