So I am running a 2002 3500 5.9l, I accidentally broke the quick connect adapter on the fuel return line. The one that is attached at the front of the truck to a nylon line then going aluminum/steel under the cab going all the way back towards the tank. I looked around for a repair kit but cannot find one locally that has a nylon line as long as the one on the truck. Seeing as it is a return line, can I replace it with a hose and clamps? Gates makes 200-250 psi hose (all fuel types friendly/resistant) I can get locally. Is there enough high pressure in the return line that I would need specifically a nylon line and the quick connect fittings versus the hose from gates and some clamps?

 

Fuel return line is only tank pressure and maybe 1 psi due to flow restrictions.

I usually replace stock fuel lines on older trucks with Gates multifuel hoses - 10mm ID for supply (Operating at max lift pump pressure so below 20 psi), 8mm for return.

I replace all of the hard lines in the frame up to the lift pump on the engine (if it's still there) because I have seen a lot of corrosion and leaks in the quick-connects due to age.

 

Mine comes off the back of the head, IIRC. Was leaking a few years back and just needed a quick snug up.....after I cut down 2 wrenches to get access back there, kinda hokey set up.

 

Thanks You so much for the info this is my first time owning and maintaining my own Cummins. I was really worried I was going to have to find that nylon line and connector.