Rajan Wilcox
Fuel lines in Fox Bodies and other muscle cars can be repaired by cutting and replacing the fuel lines, and then connecting a fuel filter to them with rubber fuel injection lines and hose clamps. The repair process can vary depending on the type of fuel line and the specific model of the car. For example, some Fox Body Mustang owners have replaced their leaking fuel flex hoses with a high-quality fuel flex hose kit from 5.0 Resto, which includes spring lock connectors and hose clamps. Others have opted for a nylon fuel line repair kit, which involves boiling the line and securing it with hose clamps. To avoid issues with fuel leaks and blockages, it is important to properly repair and maintain the fuel system in Fox Body vehicles.
Repairing Fox Body Fuel Lines
| Characteristics | Values |
|---|---|
| Fuel line repair kit | Nylon fuel line repair kit, 5.0 Resto Fox Body Mustang Fuel Flex Hose Kit |
| Fuel line material | Rubber, nylon, aluminum, steel |
| Tools | Boiling water, hairdryer, rubber tubing, hose clamps, tape |
| Steps | Cut old line, boil new line, slide over barbed fitting, secure with hose clamps, prime fuel pump |
| Parts | Fuel pump, fuel filter, fuel rails, fuel tank, fuel injectors, fuel flex hose |
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What You'll Learn
Fixing a leaking fuel hose
First, it is important to identify the source of the leak. Check for any visible cracks or damage on the fuel hose. If the leak is coming from a metal connector, it may be due to an issue with the flare on the end of the fuel line. If the hose is damaged, it will need to be replaced.
If you are dealing with a metal connector leak, the easiest fix is to remove the old flared end, slide on a new fitting, and re-flare the end using a flaring tool. Ensure that the new fitting is on before flaring the end of the line, then tighten it down. Turn on the system and check for any remaining leaks. If there is still a leak, slowly tighten the connection until the leak stops, but be careful not to wrench it too tight, as this can crack the flare and ruin the seal.
For a temporary fix, you can try to flex the hose down and reconnect the hose clamp if there is enough exposed tube. However, this is not a long-term solution, and a proper repair should be done as soon as possible.
If you are replacing the fuel hose, make sure to purchase the correct type and size of hose for your vehicle. You will also need to buy new hose clamps to secure the connection. Cut the old hose and remove it from the hard lines, then boil the new hose for about ten minutes to make it pliable. Slide the new hose onto the barbed fittings, and secure it with the hose clamps.
Finally, prime the fuel pump and check for any leaks. If there are no leaks, your repair is successful.
It is important to note that working with fuel systems can be dangerous, and it is always recommended to seek professional assistance if you are unsure about any part of the process.
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Replacing fuel lines with flexible hose
If you are considering replacing fuel lines with flexible hose, it is important to note that flexible hoses are more susceptible to damage from road debris and can be difficult to seal. They are also not suitable for long runs of hard lines. However, they can be a good option for custom-length fuel lines and offer a secure, long-lasting connection.
When replacing fuel lines with flexible hose, there are several steps you should follow. First, locate the damaged or leaking fuel hose. Place a drip pan under the fuel tank and remove the fuel hose from the fuel pump, using a fuel hose quick disconnect tool if necessary. If you are removing all three lines (supply, return, and vapour), you will need to remove the vapour line from the charcoal canister and the return line from the fuel tank.
Next, place new hose clamps around the new fuel hose, ensuring they are installed at the proper tightness. Install the new flexible hose onto the fuel pump, fuel line, or carburetor, and tighten the hose clamps to secure the hose. Do not use old hose clamps, as they may not hold and cause a leak.
Finally, test the vehicle by driving it around the block and going over different bumps to allow the fuel to slosh around inside the lines. Monitor the dashboard for the fuel level and any engine lights. If the engine light comes on, further diagnosis or a certified mechanic may be required.
It is important to note that flexible fuel line repair kits are available, which can save time and include all the necessary connectors and fittings for a complete repair. These kits often include braided stainless steel or stainless steel lines that offer maximum durability and resistance to corrosion, fuel leaks, and wear.
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Using a nylon fuel line repair kit
Prepare the Fuel Lines
Firstly, you will need to prepare the fuel lines for repair. This involves cleaning the lines thoroughly and ensuring they are free of any debris or residue. It is also important to make sure all the fuel is drained from the lines before beginning any work.
Cut and Measure the Nylon Line
Using a special cutter designed for nylon tubes, or a razor knife, cut the nylon line to the required length, ensuring a clean cut with no pinching or burrs. Measure the line carefully to ensure an accurate fit.
Heat the Nylon Line
The next step is to heat the nylon line. This can be done by boiling water and soaking the line in it, or by using a heat gun. Be careful not to overheat the line; you only need enough heat to soften the nylon so that it can be fitted over the barbed fittings.
Fit the Nylon Line
Once the nylon line is softened, quickly but carefully slide it over the barbed fittings. You may need to use a tool, such as a caulking gun or a hose press, to push the line onto the fittings if it is too tight to do by hand. Make sure the line is securely seated and won't slip off.
Secure the Line
To secure the nylon line in place, you can use hose clamps or, as one user suggests, slit a piece of rubber tubing and slide it over the nylon line, securing it on top of the barbed fittings with clamps. This will help to protect the nylon line and provide a tighter seal.
Test for Leaks
Finally, before starting the engine, it is important to test the repair. Prime the fuel pump several times and check for any leaks. If there are no leaks, you're ready to go!
Remember to exercise caution when working with fuel lines, and always ensure the area is well-ventilated.
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Upgrading the fuel tank
The first step is to remove the old fuel tank. This will be easier if the fuel tank is only a quarter full, as it will be less cumbersome and the fuel level will be below the filler neck opening. Once the old tank is removed, you can prepare the new tank. If possible, use a high-volume electric fuel pump, as these are more powerful and efficient than their mechanical counterparts. Aeromotive's Eliminator Fox Body Stealth Fuel Tank is a popular option, with a 15.7-gallon capacity and internal baffling that minimizes fuel "sloshing" and increases flow efficiency during acceleration.
Before installing the new tank, add a few strips of AmeriSeal nitrile camper tape to the top of the tank and the straps that secure it. This will act as padding to absorb vibration and prevent the tank from rattling against the bottom of the car. You can also purchase Aeromotive's fuel-pump wiring upgrade, which includes thick 10-gauge wire, a heavy-duty relay, and a circuit breaker. Use solder to link the wires and shrink-wrap to ensure they are secure.
Finally, you can reinstall the upgraded fuel pump assembly into the tank, being sure to use a new O-ring seal. The pump will require some twisting and turning to seat properly and to locate the filter screen in the tank's baffled area. It is also recommended to pick up a filler neck seal when upgrading the fuel tank, as these seals can take a set to the diameter of the filler neck tube over time and may begin to leak.
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Replacing fuel filter
To replace the fuel filter on a Fox Body Mustang, you will need to purchase a new fuel filter and a few other supplies. Here is a step-by-step guide on how to do it:
Firstly, gather your supplies. You will need a new fuel filter, four small hose clamps, and 1-2" pieces of rubber "fuel injection" fuel line. These supplies are available at most auto parts stores.
Next, locate the factory fuel filter in front of the gas tank, underneath the car. Once you have located the fuel filter, use the appropriate tools to disconnect it from the fuel lines. Be careful when handling the fuel filter, as it may contain residual fuel.
Now, take your new fuel filter and connect it to the fuel lines using the rubber "fuel injection" fuel line and hose clamps. Ensure that the rubber line is securely attached to the fuel filter and the fuel lines, and that the hose clamps are tight to prevent leaks.
Before starting the engine, it is important to check for leaks and ensure that the new fuel filter is properly installed. Cycle the switch and inspect for any signs of fuel leaks. If there are no leaks, you can proceed to start the engine and test the vehicle.
Additionally, here are some extra tips for replacing fuel lines on a Fox Body Mustang:
- You can purchase hard 5/16" brake lines from your local auto parts store, usually sold by the foot in various lengths.
- To attach the new supply and return hoses to the hard lines, use spring lock connectors made of solid aluminum with a barbed end for the rubber hose.
- When connecting the hoses, ensure you test fit the adapters to the hard lines before purchasing to ensure the correct fit.
- It is recommended to use hose designed for biofuels, as some materials may not hold up to the ethanol-blended gasoline.
- If you are using stock rails, it is more cost-effective to order new stock lines rather than converting to AN lines.
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Frequently asked questions
There are several ways to repair fox body fuel lines. One way is to use a nylon fuel line repair kit. You can cut the old line off the hard lines and boil the new line for about ten minutes before sliding it over the barbed fitting. You can also use a hairdryer to apply heat to the hose and slide it over the barbs in sections.
A quick fix for fox body fuel lines is to cut the stock fuel lines and run fuel injection hose up to the fuel rails. You can use a high-quality, properly clamped barrier-type fuel injection hose with the proper SAE certification.
To prevent fuel leaks, you can use a fuel flex hose kit to restore proper fuel flow and eliminate leaks. These kits include spring lock connectors and hose clamps to secure the new hoses and create a tight seal.
Common issues with fox body fuel lines include leaks, cracks, and blockages. Leaks can occur due to deterioration of the rubber hoses over time from exposure to heat and high ethanol content in modern fuel. Blockages can also occur, leading to fuel leaks and reduced fuel flow.
