I'm leaking fuel, looks like it is coming from behind the fuel filter at the rear of the engine. I suspect that it is the rubber return line from the injection pump but I am not sure as I cannot see the leak. I've decided to change the rubber return line and the supply line as mentioned in other posts. Mine are the original lines since new. I have read that the return line is 5/16. What size is the supply line and how long are these lines and are they attached with clamps? I plan on removing the starter and working from below. The topside is just too cluttered and tight. <br><br>Anything else I should be looking at regarding this leak? Any tips on doing this replacement will be appreciated. It looks like a very royal pain. <br><br>Truck is a stock 96 2500 2x4 k

 

One line is 3/8&quot; and the other is 5/16&quot;. Just cant remember which one is which. The rubber supply line is very short and goes between the fuel heater and the transfer pump. About 1/2 foot of this and for the return I would get 2 feet just to be safe. (Be sure to get diesel rated hose) You will need a set of pliers to push in on the clamps and move them back to get the line off of the fitting. I usually just go back with a regular hose clamp. You will probably have to go from the top to get the return line clamp off from the back of the fuel filter. I replaced both lines on a truck with a hydraulic pump for a DewEze bed, so you should be able to get in there from the top. A good tip is too remove the 2 bolts that hold the master cylinder and move it out of the way, also remove the fuel filter.


Monty

 

I beleieve the 3/8 is siupply and the 5/16 is return. This is one of the most PITA jobs on these trucks.<br>John

 

These leakin lines as the others have said are a PITA....so to make it a one time job get the best hose you can find

 

Thank you all for you comments. Just looking at the installation you can tell it is a PITA. Today I will buy the hose and get started.<br><br>Yesterday was just a bad day. After I discovered the leak, I tried to repositon the truck closer to my shop. Well, I got stuck in the Texas mud (6&quot;rain) and had to pull myself out. After I got it where I wanted it, both my trouble spotlights took a dive. I just decided to put everything off a day and that today must be a better day. I hope I am right.

 

Make sure you get diesel-rated hose and be prepared to cuss. Also bleed as much air as possible out when re-filling the filter by using the manual pump. Check the seal on the bottom of the filter housing where the heater element is located while you have it off. That can also leak but usually it sucks air and causes hard-starting, not external leakage.<br><br>Good luck.