tristan21

Ok so I broke the little quick disconnect plastic thing off my fuel tank module. Is the smaller line just for unpreassurized fuel return or what? Im tryin to get pics goin gimmie a sec I think I can get it.

tristan21

http://i177.photobucket.com/albums/w...Picture001.jpg

So there it is in all its glory. I couldnt wait till I ran outta fuel and I just made up my mind in a hurry to do it. So half a tank of fuel is heavier than you can manage even with the jack and those stinkin fuel connections are near impossible to get off of the tand and while I was fidgiting with it the tank slid off the jack. So should I try to superglue, jbweld, tap and hose it or order a whole new part? I called dodge they want $335 before tax for the part. Am I screwed or can I fix it?

8mpg

the smaller side is the return and doesnt hold much pressure... dont know what else to say Is that an intank pump like the 05+ or the 03-04 setup with the fuel pump on the frame rail? If its the small side, you could try and use a hoseclamp on it

24seven

Well tonight i did almost the same thing to mine trying to install my FASS. I got the intake and outtake line off but the electrical connector was a edited by admin and didn't want to come off. Finally broke free after breaking a piece off of it (the connector itself and thankfully not the sender unit it came off of). Really glad that I waited until my tank was EMPTY. If it was full or half I probably would have gotten killed! (and I was going to try it)

Depending on how thick the plastic is on top you may be able to drill it out and thread a brass elbow or put a grommet in there and a elbow that will hook up to the line. Don't think you will have much luck with j/b weld or glue but you could try it. I think through that since its off already you might as well do it right or close to right as possible therefore you wont risk having it break or come apart in a not so convenient situation. Good luck.

Next time I just think ill take the bed off instead

tristan21

yep take the bed off or alteast remove the tire. this day just wasnt like it was supposed to go. I was also gonna do the cp3 mod, put the new shocks on, and do the rollover/vent recall mod, but this will certainly put a stop to all that nonsense. Maybe monday I can get to it. I guess i'll have to atleast try to tap the plastic since that little plastic thingy is all thats wrong with this stupid $335 piece of garbage.

tristan21

I suppose the most irritating thing about this whole project is that it all started because the jerk from pennsylvania that runs a diesel shop (that will remain nameless only bcause I forgot his stinkin name) installed my fass in the middle of winter and screwed it all up. I was running out of gas when the overhead reads 120 miles till empty cause he cut the pickup tube 2" short of the bottom. Thats what I was fixing to start with and just decided to do the other stuff.

8mpg

I didnt read that you had FASS.. ditch that stock line.. Just run a new line from the return side of the fuel filter housing and plumb it like the Glacier kit. Buy the filler neck adapter from him, or you can get a 3/4" T from you local plumbing supply place along with a couple 3/4" NPT to 3/4" barb fittings...then just reduce the 3/4" on the middle until you can put a 3/8" barb on it.

tristan21

Maybe Im missin something here, its the little return line thats broke. Are you sayin that I can just plumb the return in anywhere in the tank? And then just plug off the broken piece up top? I didnt think of that. If thats what your sayin and you dont think it will affect the operation not goin into that hose inside the piece.

8mpg

Exactly..you are not using your stock lift pump anyways...the only thing you were using was the return line thats feeding the excess fuel from the cp3 back to the tank. So just skip it. You can plumb it onto the tank with a bulkhead or you can T into the fuel vent hose and use it. If you have the fuel vent mod, just plumb it into the old vent line. A 3/4" barb fitting into the end of the stock hose and just find a way to reduce it down to a 3/8" barb. Then just run a 3/8" fuel hose (make sure its diesel rated and run it from the fuel filter housing to your 3/8" barb fitting

tristan21

Now im wonderin why I didnt think of that. So do you have any idea why the return line came down that hose inside and all of that? Im just curious since they had it plumbed that way to begin with. I wonder why they just wouldnt have let the fuel drop straight through the barb? Not that I think it will matter.

8mpg

Do you have the intank pump? I know the intank pump return line returns the fuel into the fuel pump base (cup) and hold a good 20oz or so of fuel. This keeps the pump cool and makes the pickup stay submerged. Now on the 03-04 style, Im not sure.

I just figure that theres lots of guys running the Walbro setups and they dump the return fuel back into the vent line.

tristan21

Hey 8 thanks for the help I was unaware of how the Walbro and GDP kits went about all that as I have the fass so I was never exposed to learning how the kit is designed or the theory behind it. I was however going with the GDP kit until I trashed my stocker along side the road in Effingham, Il in 20* weather and had to do something in a hurry. But that should help alot and save me a pile-o-cash. I guess monday I will tear into it again. yay

Diesel-Dan

I dont see any issue...and that rubber plug with the spring clamp

...i have heard of folks using that for a return as well. Might look into that....would be simpler. Just tap into the stock engine return ahead of the tank on the frame....

tristan21

dan if you look at the top right the blue thing is the connector that holds the fuel line on the nipple there is supposed a nipple and a gray connector that broke off just to the right of the other one.

I dont think there is a problem anymore though as I capped the broken one off and tapped into the blue fass return line vent and put it all together and it seems to run and drive fine now. Thanks for reading the post though.

Diesel-Dan

What i meant was i don’t see any issue with the info you received.....i should have clarified.....i saw the broken return line.....had to look at it for a bit!

Be careful routing your stock engine return into the FASS return. I have had issue with this before (Most of them running the FASS return into the stock tank fitting you broke...soo...its a little different in your case). You don’t want the FASS return to pressurize the line due to flow restrictions.....BUT running the engine return into the 3/8” FASS line should be ok….just check FASS pressure and make sure its all normal……any additional restriction on this line will increase system pressure.