3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

Fuel supply line leaking at fuel tank module

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Old Aug 29, 2015 | 04:41 PM
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From: Southern California
Fuel supply line leaking at fuel tank module

2003 2500 quad cab short bed 4x4. 200K miles.
It had the Dodge retrofit done to move the fuel pump into the tank around 100K miles.

I've got a pretty good leak on the supply line. (The rearmost line) where it plugs into the fuel tank module. The fuel appears to be coming out around the end of the line, so I don't know if the plastic barb on the fuel tank module is cracked or if the fuel line is not sealing properly against the barb. I removed the line (quick disconnect), cleaned the line and the barb (nothing obvious like any dirt or grit was found), removed the the blue clip (the part that stays attached to the fuel tank module), and inspected it (nothing obviously wrong.) Then I put it all back together...no change. (It still leaks.)

The dealership says they can only sell me the whole fuel line bundle...all of the lines from the tank forward, but that the problem is most likely just the clip.

I haven't been able to source just the clip in my searches so far.

I'm looking for suggestions.
Can I buy just the clip...if so where, and is that likely to fix the problem?
Can I just replace the stock lines and quick disconnects with appropriate (diesel-safe) rubber line with hose clamps? (If so...what size?)
Can someone think of a good way to definitively ID the problem as the hose/seal rather than a crack in the barb on the fuel tank module? I Can't see any cracks, but without removing it from the truck, I don't know that I'd be able to get a good enough view anyway.

Any other help/suggestions would be appreciated.
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Old Aug 29, 2015 | 06:29 PM
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From: Southern California
Sorry guys...nevermind. It's the stupid plastic hose barb on the fuel tank module. I'll replace the module and all should be well.
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