Regan Brown
If you're having trouble with your 1985 Ford F150's fuel tank selector valve, you might be considering bypassing it. This can be done by connecting the supply line from one tank to the supply line to the high-pressure hose. You'll also need to connect the return line from the fuel rail to the return line back to the tank that you have the supply line coming from. It's important to note that you should use smooth tubing that is exactly 3/8 OD when making these connections, as using barbed fittings can damage the fuel line seal. Additionally, you'll want to remove the skid plate over the front tank to locate the selector valve on the frame rail, which is on the driver's side, just behind the cab.
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What You'll Learn
Location of the valve: driver's side, behind the cab
If you want to bypass the fuel tank selector valve on your 1985 Ford F150, and the valve is located on the driver's side, behind the cab, you can do so by following these steps:
Firstly, you may need to remove the skid plate over the front tank to access the valve. This can be done by removing four bolts, with a note that the front passenger side bolt may be more difficult to remove than the others.
Next, you will need to disconnect the supply and return lines from the valve. There are four lines on the back of the valve: two supply lines and two return lines, one of each going to each tank. You will need to identify which lines are which, and then connect the supply line from one tank to the supply line to the high-pressure hose, and the return line from the fuel rail to the return line back to the same tank.
To bypass the valve, you can use a piece of smooth tubing that is exactly 3/8" OD (outside diameter). If you have Bundy-type fuel lines, do not use a barbed fitting as it may damage the fuel line seal. Smooth tubing is recommended, and it must be the exact size specified to avoid issues.
Make sure you have plenty of buckets to catch the fuel when you disconnect the lines, especially if you have a diesel truck, as the rear tank is higher and better to use.
You can also modify the gas cap by drilling out the centre and inserting a barb, using a small compressor to get the fuel flowing. Alternatively, you can create a T-joint for both tanks using a hollow fibreglass rod, ensuring that both fill tubes are the same height to prevent overflow.
Please note that this information is based on similar procedures for the 1987 Ford F150, and the specifics may vary for your 1985 model. Always refer to a qualified mechanic or a detailed guide specific to your vehicle's make, model, and year for the most accurate and safe instructions.
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Use a 3/8 tube to bypass
To bypass the fuel tank selector valve on a 1985 Ford F150, you can use a 3/8" tube. This method is suggested for those with a diesel truck, as the rear tank is higher and better to use.
Firstly, you will need to locate the selector valve. This is found on the frame rail, on the driver's side, just behind the cab. If there is a skid plate over the front tank, you will need to remove it first.
To bypass the valve, you will need a piece of smooth 3/8" tube, around 2" long. It is important to ensure that the tube is exactly 3/8" OD, not 1/100th over or under. If you have bundy-type fuel lines, do not use a barbed fitting, as this may damage the fuel line seal. Smooth tubing is the best option.
Before disconnecting anything, ensure you have plenty of buckets to catch any fuel. You will then need to connect the return line from the fuel rail to the return line back to the tank that the supply line is coming from. You will also need to hook the returns together, and hook the supply lines together (to and from the same tank).
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Connect the return lines to the fuel rail
To connect the return lines to the fuel rail, you must first identify which lines are the supply lines and which are the return lines.
The supply line is usually larger in diameter than the return line. In some vehicles, the supply line is 5/16", while the return line is 1/4". However, in some cases, the supply and return lines may be the same size, making it challenging to distinguish between the two.
Once you have identified the return lines, you can proceed with the connection process. The return line from the fuel rail should be connected to the return line going back to the tank that the supply line is coming from. This ensures that any unused fuel is returned to the correct tank.
It is important to note that the specific steps and connections may vary depending on the make and model of your vehicle. Always refer to reliable sources and seek professional assistance if you are unsure about any part of the process.
Additionally, when working with fuel systems, it is crucial to prioritize safety. Ensure that you are wearing appropriate protective gear and that the vehicle is properly secured and prepared for maintenance before beginning any work.
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Connect the supply lines to the high-pressure hose
To connect the supply lines to the high-pressure hose, you will need to locate the hose coming from your front tank leading to the valve. The valve ports will have directional arrows that indicate which hose from the tank is going to the engine and which hose is coming from the engine. You will need to bypass the valve on both the supply and return lines.
To do this, simply splice in a section of hose in each line that is long enough to connect the lines in place of the valve. You can use a piece of smooth 3/8" tube, about 2" long, to connect the supply lines. Ensure that the tube is exactly 3/8" OD, not 1/100th over or under, as even a slight deviation will cause issues with fit and seal. If you have the Bundy type fuel lines, avoid using a barbed fitting as it may damage the fuel line seal.
If you don't want to run an entirely new line, you can use a poly/plastic fuel line component with crimp rings to join the line. Any material suited to gas at low pressure is fine. You can also swap out all the rubber for hard nylon to prevent it from being eaten up and fouling the carb.
It's important to note that you should not use clamps if you put the line onto a properly-sized hose barb. Instead, route it away or shield it from high temperatures. Additionally, make sure there is no pressure when fastening the fitting ends together, and if you use air pressure in the tank, keep it very low to avoid over-pressurizing your tank.
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You can safely plumb the fuel lines
Firstly, locate the fuel tank selector valve on the frame rail, driver's side, just behind the cab. You may need to remove the skid plate over the front tank to access it. Disconnect the fuel line from the filter using specialty disconnect clips or by fabricating your own tool with a piece of plastic tubing to disengage the safety clips. Be cautious, as fuel may spray or leak.
Next, to bypass the valve, use a piece of smooth 3/8" tubing, about 2" long. Ensure the tubing is exactly 3/8" OD, as using tubing that is too large or small can damage the fuel line seal. Connect the supply line from one tank to the supply line to the high-pressure hose, and the return line from the fuel rail to the return line back to the tank with the supply line.
Alternatively, you can modify a gas cap by drilling out the center and inserting a barb, using a small compressor to get the fuel flowing. This method, along with plumbing the fuel lines as described above, will allow your Ford F-150 to run safely on a single tank.
Remember, always exercise caution when working with fuel lines, and ensure you release the gas line pressure or drain as much gas as possible before disconnecting any lines.
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Frequently asked questions
You can bypass the valve by connecting the return line from the fuel rail to the return line back to the tank that you have the supply line coming from. You will also need to hook the supply lines together and the return lines together.
You will need a piece of smooth 3/8" tubing, about 2" long. The tubing must be exactly 3/8" OD, not 1/100th over or under.
Before disconnecting, make sure you have plenty of buckets to catch the fuel.
If you have the bundy type fuel lines, do not use a barbed fitting as you may damage the fuel line seal.
Yes, you can safely plumb the fuel lines like a single-tank truck.
