Rear Fuel Line: How to Make a New Plastic Nylon Line

[macleanflood]

So after my track bar came up like a guillotine and severed my plastic fuel line that runs from the tank to the hard line attached to the chassis I went on quite a journey making a replacement.

Here's the parts you need:

3/8s to 5/16 barbed QD fitting:

https://www.amazon.com/gp/aw/d/B000E35WJW?tag=wranglerorg-20

5/16 barbed QD fitting:

https://www.amazon.com/Dorman-800-080-5-Fuel-Line-Connector/dp/B00A19LHXE?tag=wranglerorg-20

5/16" nylon fuel line:

https://www.amazon.com/your-orders/pop?tag=wranglerorg-20

I haven't ID a good sleeve material...OEM has a foam line I assume anti abrasion sleeve.

Assembly can be accomplished three ways...heat the tube to 385 degrees...a digital heat gun works well...fuel line in a vice and shove in the barbed fitting. I tried this method but my heat gun only has a 250 and 500 setting...got it too hot and it didn't work. The barbed fitting swiveled on the fitting and leaked.

Second method...buy Dorman's fancy press tool for $100. A little heat works... boiling water or a heat gun on a lower than 385 degrees setting.

https://www.amazon.com/Dorman-800-301-Fuel-Line-Repair/dp/B000E35W1K?tag=wranglerorg-20

Third method...this works for all the cheap bastards out there like me (see web link below for an original explanation of this method.) Basically you need an old school flare tool and a caulk gun. Mount the tube in the 5/16" section of the flare tool...I found myself having to do this in stages about 1/4" to 3/8" at a time...and use the caulk gun to press the fitting into the barb. Remove the plastic rention clip first. Again a little heat helps.

https://nastyz28.com/threads/how-to-nylon-fuel-line-without-expensive-tool.220894/

@Chris you can consider this for one of the resources section posts.

These are easy enough to make and often the barbed connectors come in two packs...so make a spare.

If anyone has a suggestion for the abrasion sleeve let me know and I'll update the post.

-Mac

 

[Barrera]

Thank you for this post! I'm brand new to Jeeps after buying my late brother's '98 TJ from my sister-in-law. The jeep sat for five years since he passed. On my trip home with the Jeep, I noticed a strong gasoline smell. Long story short, the line from the fuel pump to the hard line has a small hole that squirts a nice stream of fuel when the pump runs. I'm guessing the line was replaced with a rubber hose at some point as I found worm drive clamps at the QD fitting (can't see the fitting at the pump yet).

I ordered the parts from your list and hope to tackle the job this weekend provided I can drop the tank. Two of the bolts spin so I'll need to fight those little jewels.

Short video of the fuel pump doing its job