Author Topic: Broken fuel pump/sending unit fitting....  (Read 23688 times)

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Offline squads51

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Broken fuel pump/sending unit fitting....
« on: February 25, 2011, 04:50:01 pm »
I went to start the W250 and smelled a heavy gas odor....no leaks on engine, but....noticed fuel dripping down from the fuel tank....removed the bed and found that the rubber lines needed replacing badly....also the return line fitting was broken off on an angle....picked up another (used) complete fuel pump/sending unit assembly but those fitting had been cut off to where the line connectors will not lock on....can I use JB Weld or something similar to reattach the return fitting and call it good?....or am I going to have to buy a complete assembly?....this is an 88' TBI....
98 Durango SLE Plus w/ 318 (Wife's)
97 2x xcab dakota (Transported to its final resting place)
88 W250 w/75 360 (The never-ending project)
87 Ramcharger LE w/ 360, (Hanger Queen)
86 Ramcharger LE w/ 360, (Current DD)

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    Offline bluegoat

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #1 on: February 25, 2011, 06:52:41 pm »
    I broke the supply fitting off of mine while changing the rubber line. I cut the fitting off flush with the base then carefully drilled and tapped the lid for a brass barb fitting. I used a little Teflon and pipe dope on the threads. I have had zero problems ever since
    88 W100 408/518/241 60f 10.25 rear fast ez efi 2.0

    98 3500 quadcab dually 4x4 12v/47re/241dhd

    12 dodge 1500 5.7 Laramie  (wifes ride)

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #2 on: February 25, 2011, 07:01:24 pm »
    Is there enough of the tube sticking up to use a plumbing compression fitting? or a heat shrink tubing?
    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline squads51

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #3 on: February 25, 2011, 07:49:10 pm »
    Is there enough of the tube sticking up to use a plumbing compression fitting? or a heat shrink tubing?

    No George there isn't....it is broken on an angle from right below the locking "ring" portion of the fitting to about 1/32nd of an inch from the base itself....
    98 Durango SLE Plus w/ 318 (Wife's)
    97 2x xcab dakota (Transported to its final resting place)
    88 W250 w/75 360 (The never-ending project)
    87 Ramcharger LE w/ 360, (Hanger Queen)
    86 Ramcharger LE w/ 360, (Current DD)

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #4 on: February 25, 2011, 08:31:58 pm »
    Ok, I just dug my spare out and looked, Dorman makes a fuel line repair kit (available at advanced). I would cut off the plastic quick disconnect, and use the dorman kit (cut one in half), and run it straight through the plastic, to the inside rubber hose. It will take a little cutting to get around the inside metal fitting, but you can handle it. then I would JB weld the outside after it is assembled.

    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline bluegoat

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #5 on: February 25, 2011, 08:58:52 pm »
    Jb weld will not seal in this application. Also I do not recall the return line having a rubber hose on the inside, I think it's just a little diffuser sort of thing. In a tbi application the return line can see pressures as high or higher than the supply side if it should get obstructed so I would be afraid of any kind of epoxy or sealant. Try my fix, I think you'll be pleased
    88 W100 408/518/241 60f 10.25 rear fast ez efi 2.0

    98 3500 quadcab dually 4x4 12v/47re/241dhd

    12 dodge 1500 5.7 Laramie  (wifes ride)

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #6 on: February 25, 2011, 09:15:39 pm »
    I'm looking at it right here. I don't see how you could drill & tap into a plastic lid, and have it meet the rubber hose.   {noclue}

    My idea of the repair pipe meeting the rubber hose on the inside, will contain all the pressure to the end of the return tube. The JB weld, or what ever would only be used to help seal the tank sloshing.


    Please explain your idea further, I do not understand what it is you are drilling & tapping in to.
    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline bluegoat

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #7 on: February 25, 2011, 09:37:53 pm »
    The green plastic lid on mine was thick enough to drill and tap. I did not drill all the way through  just deep enough to tap and thread in the fitting. The fittings on the underside of the lid stayed the same. I mis understood the line repair idea, as long as the jb isn't sealing a pressurized line I see no reason that it won't work. My fix may not work on all units, but it seems strange because it was the same year model
    88 W100 408/518/241 60f 10.25 rear fast ez efi 2.0

    98 3500 quadcab dually 4x4 12v/47re/241dhd

    12 dodge 1500 5.7 Laramie  (wifes ride)

    Offline bluegoat

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #8 on: February 25, 2011, 09:49:17 pm »
    After looking at the pics a little closer I think I see how I did it. It looks like between the top surface of the lid to the bottom surface where the inside nipple bolts on is almost 3/4" thick. It's hard to describe without a pic of my setup ( promise I'm not crazy)  ;D
    88 W100 408/518/241 60f 10.25 rear fast ez efi 2.0

    98 3500 quadcab dually 4x4 12v/47re/241dhd

    12 dodge 1500 5.7 Laramie  (wifes ride)

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #9 on: February 25, 2011, 09:57:39 pm »
    I understand what you are describing now, I'm just not real crazy on tapping into plastic for a pressurized line.
    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline bluegoat

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #10 on: February 25, 2011, 10:32:50 pm »
    Think of a threaded PVC fitting. Sch40 is good to 200psi. I'm not trying to stir the pot per say, it's just that I've had this very fix on my truck for a little over five years with no trouble.
    88 W100 408/518/241 60f 10.25 rear fast ez efi 2.0

    98 3500 quadcab dually 4x4 12v/47re/241dhd

    12 dodge 1500 5.7 Laramie  (wifes ride)

    Offline squads51

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #11 on: February 26, 2011, 09:50:21 am »
    Off to Advance in just a bit for some repair line....will let you know how it goes....maybe, just maybe, there may be some before and after pics....
    98 Durango SLE Plus w/ 318 (Wife's)
    97 2x xcab dakota (Transported to its final resting place)
    88 W250 w/75 360 (The never-ending project)
    87 Ramcharger LE w/ 360, (Hanger Queen)
    86 Ramcharger LE w/ 360, (Current DD)

    Offline bluegoat

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #12 on: February 26, 2011, 05:04:22 pm »
    Off to Advance in just a bit for some repair line....will let you know how it goes....maybe, just maybe, there may be some before and after pics....
    .         Damn.... Looks like superburban gets the commission on this one. Lol
    88 W100 408/518/241 60f 10.25 rear fast ez efi 2.0

    98 3500 quadcab dually 4x4 12v/47re/241dhd

    12 dodge 1500 5.7 Laramie  (wifes ride)

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #13 on: February 26, 2011, 05:08:43 pm »
    no, all ideas are worth posting up for consideration, its not a contest. I talked with Paul on the phone, and he had a problem getting the right stuff, so we still do not know what his final outcome was.
    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline bluegoat

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #14 on: February 26, 2011, 05:25:05 pm »
    I'm just kidding. Like I said now that I understand your idea I think it's as good as mine. And probably easier in the end
    88 W100 408/518/241 60f 10.25 rear fast ez efi 2.0

    98 3500 quadcab dually 4x4 12v/47re/241dhd

    12 dodge 1500 5.7 Laramie  (wifes ride)

    Offline squads51

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #15 on: February 27, 2011, 07:50:51 pm »
    .         Damn.... Looks like superburban gets the commission on this one. Lol


    no, all ideas are worth posting up for consideration, its not a contest. I talked with Paul on the phone, and he had a problem getting the right stuff, so we still do not know what his final outcome was.


    I'm just kidding. Like I said now that I understand your idea I think it's as good as mine. And probably easier in the end


    After careful consideration of the various options presented both on here and a few long distance calls....and I thank you all for your thoughts on this problem....I give you all the results:

    Pic #1....removed the bed



    Pic #2....source of fuel leakage, old hoses and broken fitting


    Pic #3....closer view



    Pic #4....pump/sending unit out of tank and draining residual gas



    Pic #5....another unit I got from Leon, unfortunately the fittings had been cut off at the locking ridge,
                 so I used it as a "practice" piece....



    Pic #6....unit dis-assembled



    Pic #7....hole drilled out same diameter as new fitting



    Pic #8....new fitting installed and re-assembled



    Pic #9....side view of unit



    Pic #10....JBWeld used to fill/close any gaps between fitting and plastic top



    Pic #11....boot/sleeve that unit sits in at bottom of tank



    Pic #12....finished product re-installed in tank



    Now to put the bed back on....or hold off for a little bit and see if another, more heavy duty one, shows up in the yard.... ::)

    « Last Edit: November 29, 2017, 09:20:45 pm by SuperBurban »
    98 Durango SLE Plus w/ 318 (Wife's)
    97 2x xcab dakota (Transported to its final resting place)
    88 W250 w/75 360 (The never-ending project)
    87 Ramcharger LE w/ 360, (Hanger Queen)
    86 Ramcharger LE w/ 360, (Current DD)

    Offline rb89318

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #16 on: June 21, 2011, 08:13:22 pm »
    Did the fix end up actually working? My wife suggested mimicking the draw straw set up out of the diesels to fix ours since the supply broke off on ours.
    Formerly rb70383
    89 Ramcharger 5.2/auto
    85 D350 Crew

    Offline squads51

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #17 on: March 18, 2015, 12:17:16 pm »

    Did the fix end up actually working? My wife suggested mimicking the draw straw set up out of the diesels to fix ours since the supply broke off on ours.


    Yes, no more fuel leaking....
    98 Durango SLE Plus w/ 318 (Wife's)
    97 2x xcab dakota (Transported to its final resting place)
    88 W250 w/75 360 (The never-ending project)
    87 Ramcharger LE w/ 360, (Hanger Queen)
    86 Ramcharger LE w/ 360, (Current DD)

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #18 on: April 13, 2016, 10:46:05 pm »
    bump
    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline DODGEBOYS

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #19 on: April 17, 2016, 07:39:04 am »
    George this should be in the F&Q section or a Howto
    put your truck info HERE
    MOPAR TO YA!!!!!! AARON HOWORD TOWNSEND / SLANTEDMIND---GOD BLESSDODGEBOYS FSM STORE
    [email protected]
    former Parts Mgr & A1 Tech @ Pete's Chrysler -Plymouth
    DO NOT use the site IM,s to contact me  l have them turned OFF

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #20 on: April 17, 2016, 10:09:18 am »
    I agree, I prefer the How Too's, But they take a bit more then just transfering. I added it to Joe s's index above for now.
    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline Bluedodge4x4

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #21 on: April 17, 2016, 10:38:55 am »
    Did you re use the plastic 90 degree fitting between the new nipple and the rubber line?
    1988 Dodge W100 318 727trans np241 Dana44/9.25 on BFG AT 31x10.5 R15

    Offline SuperBurban

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #22 on: November 28, 2017, 01:32:19 am »
    Just using this post to hold the pics so they can be put in the above posts.
    « Last Edit: November 29, 2017, 09:19:21 pm by SuperBurban »
    77 W200, 360/727/NP203/D44HD/D60 (Wifes Toy)
    77 M887- 318/727/NP203 D44HD/D60
    78/86 Ramcharger.  360/727/NP203 D44/9&1/4
    85/89/90 D150/W250 5.9TBI/435/241 D44HD/D60HD
    85 W350 360/727/241 D44HD/D60
    97 B3500 5.9MPFI/518 D60HD
    20 Pacifica Hybrid, 3.6 V6, EVT 1 speed trans.
    projects:
    85 Country Coach RV, 5.9 Cummins/TH475,GV od,US gear Exhaust brake,D70HD (4 wheel disk brakes, 10 lug 19.5 rims.

    Offline masterjay23

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    Re: Broken fuel pump/sending unit fitting....
    « Reply #23 on: December 16, 2017, 09:39:05 pm »
    The elbow connector broke on mines too after changing it out. I wish I could have given it a stronger plastic one or steel elbow. Lucky enough this auto place here stocks super old parts and ordered me a 90 degree angled on with the proper hose.

     

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