So, I've read that some people are having trouble with the push-lock connectors leaking air into the system, particularly the one that connects to the tank. Does anybody have a feel for whether or not this is the norm? I'd like to use the push-locks, but I won't waste my time if they are doomed to leak.

This is one impressive unit - weighs a freakin' ton.

 

Probably doesn't help your problem but reinforces your purchasing decision!

Very interested to hear what you think of it!
Dave

http://www.off-road.com/dodge/reviews/FASS/May_04/

 

Mine was clamped on since it leaked air. I would do it right the first time and just spend the 29 cents at Lowes for a 3/8" hose clamp and eliminate any future problems.

brnadon.

 

When Keith at Forest City Diesel installed mine, we used hose clamps. I do not like or trust that snap on stuff.

 

I also double hose clamped mine at the tank.....
Didn't bother with the push-on. I couldnt see putting a fuel system like this on and starting with a connection like that Other than that its a killer system though

 

Add to the want-list...

 

Well, the install went fairly painlessly, other than having to crack the line at the injection pump to prime the system and spraying diesel all over the place (tried bumping the starter and letting the pump run many times, but no fuel to the engine without cracking the line).

I didn't use the quick-connect fitting for the tank suction line; just hose-clamped it on very tightly. Plus I hose-clamped all the pushlock connections. I also made sure I used thread compound that was suited to exposure to fuel for all the NPT fittings.

After an initial leak inspection and test drive, I was off for a 300 mile holiday trip. As far as performance goes, the truck loves the thing, and it feels strong and really does idle more quietly (I now have strong suspicions that the factory system was sucking air at the tank connector). But, I spent most of the holiday weekend on my back soaked in diesel fuel fighting leaks.

First, the cheapo factory hose clamp for the filler hose at the tank snapped and a slow leak developed there. That was easily fixed (I replaced the other cheapo clamp on the other end while I was at it), but them every time I'd park the truck there'd be a couple drips on the gound under the FASS unit, and eventually the entire unit was coated in a thin film of fuel. Of course every connection that I made was rechecked several times, but no joy. At this point I can't really say where it's leaking from, but it doesn't seem to be from any of the fuel line connection points; in fact it seems to be coming from somewhere on the top of the unit.

Next step I guess is to drop the unit and check all the bolts that hold the manifold together and to try to see where it's leaking from. Frustrating...

 

I have had zero issues with leaking on a FASS that i had used GOBBS of Tefflon tape on. The push lock fittings, if installed correctly will hold just fine. I use tons of WD40 and a heat gun to install them. It is very important to get the lines all the way up to the yellow collars. I have never had any leak or suck air from thoes fittings.

Like you, i hate thoes hose clamps they send with the kit. I usally install the single band units over those prone-to-brake Dual band units. I cant count how many i have broken.

The biggest problem i had with leaks were thoes clamps and the pressure line fitting (the on that screws into the FASS Body) going to the VP44. (side twards the fnt of the truck, fitting on the top). The ones that i didnt use tefflon tape on, they leaked bad. The ones i did use the tape, no probs. Mine is as dry as the day i put in on. My bosses, it leaks...but i didnt use tape. ALSO you will have some fuel back out of the old line that will run down from the top of the tank the first few days after you install the FASS. BUT it usally lasts about a week at most. I would use some brake cleaner and clean it up as best as you can. Then run it and see where the fuel is comming from. should be pretty simple.

Dan

 

I also thought I had a leak when I first installed my Fass. Turned out to be dripping out of the original fuel supply line not being used above the tank. About 2 cans of brake clean and a couple of cleanings to pinpoint. After a couple days it quit (all the fuel had drained out). Next month will be a year since I installed mine, no problems at all. Tim

 

My quick connect sucked so much air I couldn't get fuel pressure from the FASS. A hose clamp sured that. I still think I have a leak someplace though, as it gets harder to start when fuel level is 1/4 tank or lower. This might be in the pickup tube though.

My FASS, or at least that's what it appeared to be, leaked real bad a few weeks ago, on the way back from Tim's, but the next day it stopped and hasn't leaked since. It appeared to be coming from the top someplace also. Reading Tim's post above, I wonder if it could have been my old fuel line, but why would it start to leak 8 months after the FASS install?

Chris

 

Yes, the fuel from the stock system left a big puddle under the cab, leaking from the frame rail the first time I parked it, but luckily I figured that out pretty quickly.

I've got my tank down to <1/8 full to see how the system works and so far like a champ, so suction seems good.

On the bright side, the fuel coating the FASS is protecting it from the salt-fest going on in New England at the moment. Next purchase will be the left-off-at-the-factory fender liners to keep the FASS out of the sh*t a bit more.

 

The Fass seems to do exceptionally well in low fuel situations - I just got back from filling up my QC shortbed with 26.954 gallons of fuel. The fuel pressure was great up until I pulled under the fueling island. Then the FP gauge started jumping from 5-17lbs until I shut it off a few seconds later. My in-tank pickup was modified... it's just a 3/8" hose from the top of the tank to the bottom of the tank, zip tied to the side of the stock sending unit. I should go buy a lottery ticket - I'm feeling lucky!

brandon.

 

Why fix whats not broke!? Might be a cheap fix for any cativation (between the tank and FASS) that might happen. Especally with the 150 GPH Units.