Fuel Rail Connectors

[Desert Patina]

Hello again, and once again thanks for all your invaluable help. I am sad to report that the brittle plastic gremlins have struck my project once again.

I've just come from measuring the fuel rails and fuel lines on my SVO, which is by no means trusted as stock. I measured the fuel rails between the main rail and any fitting flaring, and I hope that is the right place to measure them.

Here's what I got. My fuel rail has two lines, one is 3/8" and the other is 1/4". The nylon line that runs to both is the same size at 5/16"

So if that is right, than these should be reasonable replacement fittings?

http://www.dormanproducts.com/p-20639-800-085.aspx
http://www.dormanproducts.com/p-12456-800-083.aspx

[MikeFleming]

Both feed and return hoses are 5/16". The pressure feed side fittings are all, stock, 5/16" quick-connect fittings that use replaceable, push-in retaining clips. The return line duckbill fittings are 1/4".

[Desert Patina]

Well that makes sense. That is why the Dorman clips didn't work on the smaller line, they don't seem to have 1/4 inch push clips.

[Desert Patina]

Hmm, such a piece of plastic is starting to make me feel so SLOOL. Seems a shame to lose another stock item and have to hunt for a replacement fuel rail that has connectors I can buy.

[TheSVOTrust]

Clips ONLY are
N806191-S1901
N806190-S1901

Fitting with new orings and clips are also sold.
Mark

[Desert Patina]

Both are an 1/8 of an inch too big from the measurements above, or one is 1/4 inch too big and the other just right. I've used them, and it is a real pain trying to get one to fit the smaller 1/4 line but the 3/8 fits well enough on the 5/16.

Also, there's no O-rings on the connectors I have, there's a nylon surface on the inside that slips over the stainless steel. Granted, I can't speak for how they are supposed to be, just how they are.

What might save me from this is that it appears the fuel rail has the same fittings as fuel filters, so maybe any clip meant to fit the ford fuel filter will do (but there is nothing for the 1/4" still).

(update? It looks like the 2003/4 Expeditions used a fuel filter with a 1/4 fitting.)

(update2? Also called Bundy Fittings?)

All in all my confidence is restored in the Dorman fittings, seeing that quick-connect is a trademark for a fitting specification and all.

[Desert Patina]

Instead of the 3/8 fitting noted in the first post, I'm using this one...

http://www.dormanproducts.com/p-13751-800-080.aspx

They are both on the way. I'll let y'all know if they work or not.

[TheSVOTrust]

They are Bundy fittings - there are O-rings internal these will work.

Cut off old Bundy
Boil water in microwave
Immerse end of tube 1/2 inch into water ONLY
use new Bundy to open tube so you can get TWO of all of the barbs into the tube TAKE OUT
Reheat water do 1 inch of tube
Using a twisting pushing (lots of force, but not enough to kind line) this time see if you can get to all of the barbs.
If you kink the line cut and start over.

Mark
P.S. You couldn't wait two months for me to be there ! LOL You guys in the areas that are warm in the winter. (Best time to drive) WE close up shop and switch to buying stuff.

[Crashman699]

Both feed and return hoses are 5/16". The pressure feed side fittings are all, stock, 5/16" quick-connect fittings that use replaceable, push-in retaining clips. The return line duckbill fittings are 1/4".

Hey Mike, is there dorman part #s for both lines??? I've been looking and it seems #800-053 might be the return (duck bill type) but I can't see one for the "reusable retainer style for the pressure side of the injector rail??

[MikeFleming]

Yes, there are Dorman numbers for both the end fittings and the "fitting + 18" attached tubing". I will need to search for the numbers. The replacement fittings have changed over the decades.

[Corrugated]

I was able to find all these fuel parts, lines and clips on the Rock Auto site. Just need to search under Tools and Universal Parts (I believe)...

[Crashman699]

Thanks mike!
I managed to find the following info...
Dorman #800-050 for the pressure line (5/16" tube, 5/16" fitting
Dorman 800-053 for the return line (5/16 tube, 1/4" fitting

[MikeFleming]

Sweet! Rvrn Amaaon carries one of those.

If you need the proper tool to assemble the fittings, let me know. It's in a box in the shop somewhere - just need to locate it.

[rodster]

Sweet! Rvrn Amaaon carries one of those.

If you need the proper tool to assemble the fittings, let me know. It's in a box in the shop somewhere - just need to locate it.

I dare you to find it and post a picture of the mystery tool. ;)

[MikeFleming]

I dare you to find it and post a picture of the mystery tool. ;) Locating it is a worthy task indeed. But pictures Ialready have!