Rusty Fuel Lines: Replacing lines not enough

[JorgeS]

My fuel lines were very rusty. There are many flexible lines available, and after looking over reviews, I bought a set of Dorman; they look very well made.
I raised the truck on jack-stands. I was unable to get the rear fitting (to the nylon line) off, and after other setbacks, I decided to take it in to a very good & reputable shop in town. With 140,000 miles, I also decided to get the fuel pump replaced.
The surprise was that the outlet from the fuel pump was in even worse shape than the fuel lines. I had started smelling gas in the last week or so, and it appears that the leak was between the body of the fuel pump and the fitting to the nylon line. The pump outlet line was so badly rusted that they were unable to get it off the nylon line and had to replace it also. Sadly, I didn't think of taking a photo of the issue.
The moral of the story is: If you're replacing rusty fuel lines, replace the fuel pump also. If you don't, the outlet of the fuel pump will be your failure point.

 

[Cadillacmak]

That is a good point you have there, thanks for sharing it on the forum for future people seeking the same problem.

 

[ORVietVet]

Rust! I hate hate hate it. Causes so many problems. I belong to other forums, owned by the same owners here, and rust is often involved in "problem" threads.

 

[stutaeng]

I missed this post @JorgeS...

Everything running well? For the first time in my life, I replaced a fuel pump on these GM vehicles a few months ago: 2004 Suburban 2500 4x4 LQ4. Was kinda a PIA, and the auxiliary tank didn't help.

Can you post a photo of your complete truck? I just happen to be chatting with my buddy and the topic of the Rams being the same lug nut pattern as our GMs came about...What years from Ram did they switch to 6 lug? How do you like your wheels?

 

[JorgeS]

Running just fine; getting ready to start a 3500 mile trip on it with my wife and our dog.
I believe 2019b was the first yeat for 6-lug Rams.
I like the wheels because they have a simple design that looks rugged without looking massive.

 

[Cadillacmak]

Running just fine; getting ready to start a 3500 mile trip on it with my wife and our dog.

3500 miles? Are you coming to Alaska?

 

[JorgeS]

Haha...3500 total, not one way!

 

[AuroraGirl]

My fuel lines were very rusty. There are many flexible lines available, and after looking over reviews, I bought a set of Dorman; they look very well made.
I raised the truck on jack-stands. I was unable to get the rear fitting (to the nylon line) off, and after other setbacks, I decided to take it in to a very good & reputable shop in town. With 140,000 miles, I also decided to get the fuel pump replaced.
The surprise was that the outlet from the fuel pump was in even worse shape than the fuel lines. I had started smelling gas in the last week or so, and it appears that the leak was between the body of the fuel pump and the fitting to the nylon line. The pump outlet line was so badly rusted that they were unable to get it off the nylon line and had to replace it also. Sadly, I didn't think of taking a photo of the issue.
The moral of the story is: If you're replacing rusty fuel lines, replace the fuel pump also. If you don't, the outlet of the fuel pump will be your failure point.

every gm product from this era had no problem like this, yet gm made it every gmt800 was susceptible. Impressive

 

[JorgeS]

Yes, we could have said: GMT800 is the best GM truck line
Instead, we say: GMT800 is the best* GM truck line
* except for brake & fuel lines

 

[ORVietVet]

Yes, we could have said: GMT800 is the best GM truck line
Instead, we say: GMT800 is the best* GM truck line
* except for brake & fuel lines

If you live in a salt free roads state, those lines are not a problem.

I used to live in KC, Mo. for gobs of years and saw the rust through on many components, including lines, in the shops I was in. had a brake line let go on an off ramp one day. Scared the ever lovin' crap out of me. Fancy steering, praying to the Lord, and people paying attention to my horn and a long enough road that got me thru 2 stop signs and in and out of a parking lot. Had to pry me off the seat. It was an automatic in a mid 60's Chevy pickup. My park brake failed me, too.

 

[stutaeng]

Agree with @ORVietVet . The fuel lines, brake lines or frame rot are not an issue in the non-rustbelt parts of the US. Pull any line from the junkyard from any GMT800 and they look perfectly fine and serviceable. I watch some YT channels on auto diagnostics including South Main Auto and see that basically anything that's not plastic and metals/alloys of sorts, will rot in his environment, regardless of make, model or anything.

To sound dumb, prior to joining the truck forums a few years ago, I had no clue what "rockers" were. That's kinda embarrassing now that I think about it but I'm being honest.

 

[ORVietVet]

Agree with @ORVietVet . The fuel lines, brake lines or frame rot are not an issue in the non-rustbelt parts of the US. Pull any line from the junkyard from any GMT800 and they look perfectly fine and serviceable. I watch some YT channels on auto diagnostics including South Main Auto and see that basically anything that's not plastic and metals/alloys of sorts, will rot in his environment, regardless of make, model or anything.

To sound dumb, prior to joining the truck forums a few years ago, I had no clue what "rockers" were. That's kinda embarrassing now that I think about it but I'm being honest. View attachment 4840

The South Main Auto guy, reminds me of me. He likes to have fun at the job and pesters those around him. He also knows his stuff. I only know "some of my stuff".

I hate dealing with rust and am glad to live in a state with no salt on the roads around here and no sales tax.

 

[99Sierra2500]

As a mechanic in this area, the worst is that salty rust flake in your eye, try to pull it out with a magnet or something, it stings like crazy, use eye wash.

 

[ORVietVet]

Or wear safety glasses. One time, I was in a shop and machining drums for a brake job. I was not wearing safety glasses. I leaned in, while it was turning/cutting, and got a speck of drum metal in my eye. Had to go to hospital and get it out. No fun at all.

 

[AuroraGirl]

Agree with @ORVietVet . The fuel lines, brake lines or frame rot are not an issue in the non-rustbelt parts of the US. Pull any line from the junkyard from any GMT800 and they look perfectly fine and serviceable. I watch some YT channels on auto diagnostics including South Main Auto and see that basically anything that's not plastic and metals/alloys of sorts, will rot in his environment, regardless of make, model or anything.

To sound dumb, prior to joining the truck forums a few years ago, I had no clue what "rockers" were. That's kinda embarrassing now that I think about it but I'm being honest. View attachment 4840

Idk what they are either

 

[stutaeng]