I started to notice hard starts today and smelled a little diesel. Looked under the truck and the Dorman fitting on the return is leaking. The tee looks good on the return and is not leaking I am happy about that. I decided to remove the Dorman fitting off the return but cannot get it off. I have tried everything but can't get it to move. I hold the plastic end with two figures and try pulling but won’t move. Does anyone have any ideas to remove the fitting. Remember it is at full arms length from under the truck and just room for one hand maybe two. The pipe looks to be steel so I am sure it is rusted. Has anyone cut this fitting off and how did you do it. I already have a compression fitting down on the stainless steel return line and going to rubber fuel line and now it is connected to the old Dorman fitting with two hose clamps. I have a new Dorman fitting to take place of the old fitting that leaks which will not come off. Need help.

 

had the same issue this summer with my '99 dealer had to remove the metal fitting from block, and cut plastic line from the steel return, then put on rubber hose with clamps from fitting to the steel line then reattach to block and line.

 

Well I had to cut it off with a hand held hack saw. I had to remove fuel filter to get the room to even get near the fitting. I can tell you there was no way that was coming off.
I cutting the fitting in the middle and cut the steel pipe also. There was rust and it looked like a aluminum insert around the steel pipe for the Dorman fitting to go on to. To get things going I put the 5/16 fuel line over the steel line and double clamped it for now. To test this for leaks it takes a hour to assemble everything to test for leaks. It worked and held the pressure. I still want to remove the lower piece from the tee and replace the steel line Cummins part number 3942592