Replacing Fuel Lines: 87 Bronco's Step-By-Step Guide

If you're looking to replace the fuel lines on your 1987 Bronco, you're in the right place. This is a job that many Bronco owners have tackled themselves, and there are a few different approaches you can take. You could opt for rubber hoses, reuse the pre-formed metal pipe with new hose, or buy a complete fuel line kit.

There are a few different options for the type of fuel line to use. Some popular choices include nylon lines, braided lines, and stainless steel lines. You can find these at auto parts stores, online retailers, or specialist Bronco suppliers. It's important to ensure you get the correct size and type of line for your Bronco, and that you have the right tools for the job, such as a flaring tool and tubing bender if you're working with metal lines.

In addition to the fuel lines themselves, you may also want to replace the fuel filter and ensure you have good-quality hose clamps. It's worth noting that some Bronco owners have reported issues with the fuel line connector at the fuel pump that goes to the carburetor, so keep an eye out for any leaks or stripping.

By following the advice and experiences of other Bronco enthusiasts, you should be able to successfully replace the fuel lines on your 1987 Bronco.

The type of fuel line to use

When it comes to the type of fuel line to use for your 87 Bronco, there are a few options and considerations to keep in mind. Here are some detailed instructions and suggestions:

Firstly, it is important to distinguish between the different fuel lines in your Bronco. There are the smaller rubber fuel lines under the hood, typically 5/16" or 3/8" in diameter. For these, you can simply buy replacement fuel lines from any auto parts store, ensuring that they are meant for fuel applications. You can cut them to the appropriate length if needed. It is recommended to replace these lines with new clamps as well.

Next, there is the rubber hose between the filler neck and the fuel tank. For this, you may need to look for a commercial hose maker or supplier. You will need to measure the diameter of the filler neck to get the correct size. It is recommended to use a hose that is suitable for fuel applications and to buy a little extra to ensure it reaches without stretching.

Now, let's discuss the hard metal fuel lines. These can be a bit more challenging to replace, and you may want to consider buying pre-bent lines specifically designed for the Bronco. This ensures a proper fit and can be safer, especially if you plan to do any off-roading. Some people choose to fabricate their own lines, but it can be tricky to get the correct bends.

As for the type of material to use, there are a few options. Braided stainless steel lines are a popular choice for their durability and ease of installation. They can be a bit more expensive but are worth considering for their longevity. Another option is nylon fuel lines, which some Bronco owners have used without issues. However, there are concerns about their long-term durability, especially under heavy use or abuse.

Finally, you can also consider using a fuel line kit specifically designed for the Bronco. These kits usually include all the necessary lines and fittings, making the replacement process more straightforward. Some kits use nylon lines, while others may offer different materials. Be sure to read reviews and get input from other Bronco enthusiasts before choosing a kit.

In summary, when replacing the fuel lines in your 87 Bronco, consider the type of line, the material used, and whether to buy pre-made lines or fabricate your own. Always use high-quality fuel lines and clamps, and don't stretch lines to make them fit – it's better to have a little extra length to work with. By choosing the right type of fuel line and taking your time with the installation, you can ensure reliable fuel delivery and enjoy your Bronco for years to come.

How to measure and cut the fuel line

To measure and cut the fuel line for your 1987 Bronco, you'll need to follow a few steps to ensure an accurate fit. Here's a detailed guide:

Measuring the Fuel Line:

• Identify the location of the fuel line: Start by locating the fuel line you need to replace. It could be under the hood, between the filler neck and the tank, or elsewhere.
• Determine the type of measurement: Fuel lines are typically measured by their inner diameter (ID) or outer diameter (OD). For fuel lines, it's usually the inner diameter that matters, as this affects the flow of fuel.
• Use the right tools: Calipers or vernier callipers are the best tools to get an accurate measurement of the inner and outer diameters of the fuel line. If you don't have access to these tools, you can use drill bits for a rough estimate, but this method may not be as precise.
• Consider fuel type: Keep in mind that different fuels require different fuel line sizes. If you're using ethanol or methanol, you'll need larger fuel lines than if you're using gasoline.
• Measure the old line: Measure the old fuel line to get an idea of the size, but keep in mind that it may have shrunk over time. It's always best to measure the fittings and connections where the line attaches to ensure an accurate fit.

Cutting the Fuel Line:

• Measure twice, cut once: Before cutting the new fuel line, double-check your measurements. It's better to have a little extra line that you can trim than to cut it too short.
• Use the right cutting tool: A tube cutter is ideal for cutting fuel lines, as it provides a clean, straight cut. You can also use a razor blade or a sharp knife, but be very careful to cut only the fuel line and not your fingers!
• Cut the line straight: Ensure that you cut the line straight and that there are no burrs or sharp edges that could damage the fittings or affect the flow of fuel.
• Test the fit: Once you've cut the new fuel line, test the fit by inserting it into the fittings or connections. It should fit snugly but not too tightly. If it's too loose, you may need to use a smaller line or adjust the fittings.
• Secure with clamps: Use high-quality hose clamps to secure the fuel line in place and prevent leaks.

Remember, safety should always be your top priority when working with fuel lines. Ensure proper ventilation, avoid open flames or sparks, and wear protective gear, including gloves and eye protection.

The best place to buy a fuel line

When it comes to buying fuel lines for your 1987 Bronco, there are a few options to consider.

Firstly, it is important to determine the type of fuel line you need. Some options include nylon, braided stainless steel, or rubber fuel lines. Each has its own advantages and disadvantages in terms of durability, ease of installation, and cost.

For example, nylon fuel lines are known for their ease of installation, while braided stainless steel lines are more durable but may be more challenging to bend and install. Rubber fuel lines are also an option, but they tend to dry rot over time, so replacement may be necessary.

Once you have decided on the type of fuel line, there are several places you can consider purchasing from:

• Online retailers: Websites such as Amazon offer a wide variety of fuel lines for different vehicle models, including powersports fuel lines and marine fuel lines. They provide detailed product descriptions and customer reviews, making it easier to find the right product.
• Auto parts stores: Local auto parts stores are a convenient option and usually stock fuel lines for various vehicles. They can provide advice and recommendations based on your specific needs.
• Specialty websites: Websites like LinesToGo offer pre-bent replacement lines specifically designed to fit your Bronco, ensuring a perfect match to the OEM factory lines. They also provide installation instructions and have live agents available to answer any questions.
• Local hose suppliers: For custom applications or unique Bronco models, you can consider contacting a local hose supplier. They can provide fuel lines of different materials and sizes, ensuring you get the exact product you need.
• Dealerships: While dealerships may be more expensive, they can provide fuel lines specifically designed for your Bronco model, ensuring a perfect fit.

When purchasing fuel lines, it is important to consider the quality and safety of the product. Some fuel lines are designed to be ethanol-compatible, while others have insulation to protect against heat from the engine or exhaust. It is also crucial to follow the recommended replacement guidelines and properly install the fuel lines to ensure your safety.

Additionally, it is worth considering joining online forums or communities dedicated to Bronco enthusiasts. These platforms often provide valuable insights, recommendations, and feedback from other Bronco owners who have gone through similar replacement projects.

By considering your specific needs, budget, and the availability of products, you can make an informed decision about the best place to buy fuel lines for your 1987 Bronco.

Whether to use hose clamps or connectors

When it comes to securing fuel lines, hose clamps and connectors play a critical role in ensuring safe and efficient vehicle operation. Here's a detailed discussion on whether to use hose clamps or connectors when replacing fuel lines on an '87 Bronco:

Hose Clamps vs. Connectors

The choice between hose clamps and connectors depends on several factors, including the type of fuel line, the application, and personal preference. Both options have their advantages and are suited for different scenarios.

Hose Clamps:

Hose clamps are designed to secure hoses to fittings or nipples, creating a tight seal that prevents fuel leaks. They are essential for maintaining fuel line integrity and preventing dangerous situations. There are several types of hose clamps, including worm-drive clamps, T-bolt clamps, spring clamps, and ear clamps, each with its strengths and weaknesses.

Worm-drive clamps are the most common type, offering versatility and easy adjustment. However, they may not provide an even seal if not installed correctly, and there is a potential for over-tightening, which can damage the hose. T-bolt clamps, on the other hand, are heavy-duty and provide a more secure and uniform grip, making them ideal for high-pressure applications. Spring clamps are often used in cooling systems as they automatically adjust their tension with temperature changes, ensuring a consistent seal. Ear clamps, also known as Oetiker clamps, provide a permanent and tamper-proof connection but require special tools for installation and are non-reusable.

When using hose clamps, it is crucial to select the appropriate type and size for your specific fuel line and fitting. Proper installation is essential, including positioning the clamp correctly, tightening it evenly, and ensuring a secure fit without over-tightening.

Connectors:

Connectors offer a quick and convenient way to connect and disconnect fuel lines, especially in applications where frequent disconnection is necessary. They are commonly used in marine and boating contexts, where fuel tanks need to be removed or disconnected regularly. Connectors can provide a secure and stable connection without the need for clamps in some cases.

Factors to Consider:

When deciding between hose clamps and connectors for your '87 Bronco, consider the following:

• Application: Determine whether your Bronco requires frequent disconnection of fuel lines, as in the case of removing fuel tanks. If so, connectors might be more convenient.
• Pressure and Vibrations: Hose clamps are ideal for absorbing vibrations and maintaining a secure connection, especially in high-performance vehicles. If your Bronco is used for off-roading or experiences intense vibrations, hose clamps might be a better choice.
• Temperature Fluctuations: Spring hose clamps are specifically designed to adjust to temperature changes, ensuring a continuous seal. If your Bronco operates in varying temperature conditions, spring clamps could be advantageous.
• Ease of Installation and Removal: Hose clamps can be more challenging to install and remove, especially T-bolt and ear clamps. Connectors often provide a quicker and easier solution for connecting and disconnecting fuel lines.
• Durability: Hose clamps made of stainless steel offer superior corrosion resistance and longevity, making them ideal for harsh environments. If your Bronco is exposed to moisture or chemicals, stainless steel clamps could be a better option.

Best Practices:

When working with fuel lines, it is crucial to prioritize safety and proper maintenance. Here are some best practices to consider:

• Regularly inspect your fuel lines for any signs of wear, cracks, or leaks. Check hose clamps for security and look for visible damage.
• Address any issues immediately. Replace worn or damaged fuel lines and clamps as part of routine vehicle maintenance.
• Choose the right type and size of hose clamp for your specific fuel line and fitting. Ensure a secure fit without over-tightening, which can damage the hose.
• Consult a professional if you are uncertain about the condition of your fuel system or the best course of action.

In conclusion, both hose clamps and connectors have their advantages, and the decision depends on your Bronco's specific requirements and operating conditions. Prioritize safety, durability, and proper installation to ensure a well-maintained fuel system.

How to remove the old fuel line

To remove the old fuel line from your 1987 Bronco, you'll need to start by gathering the necessary tools and materials. These include a new fuel line, a razor blade, and hose clamps. It's also recommended to have a fuel line removal tool on hand, which can be purchased or rented from an auto parts store.

Begin by locating the fuel lines. The rubber fuel lines are typically found under the hood, and the filler hoses are between the tank and the gas filler neck. You may need to cut the old lines with a razor blade to remove them, being careful not to damage any surrounding components.

Take note of the size of the lines you're replacing so that you can purchase the correct size for your new fuel line. The rubber fuel lines are typically 5/16" or 3/8" in diameter, while the filler hose may be larger, around 5/8". It's important to buy high-quality fuel line that is designed for gasoline and to get the correct type, such as nylon or stainless steel, depending on your preference and budget.

When you're ready to install the new fuel line, cut it to the appropriate length, leaving a little extra to ensure a proper fit. Use hose clamps to secure the new line in place, being careful not to overtighten the clamps as this can damage the line.

Finally, be sure to dispose of the old fuel line properly. Old fuel lines can be recycled or disposed of at a designated hazardous waste facility.

Frequently asked questions