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Power Strokes 1994-1997 General Technical discussion of topics related to vehicles powered by the Power Stroke engine in 1994 through 1997 models.

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Old 01-15-2013, 11:38 PM   #1 (permalink)
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Massive Fuel Leak

Was driving my truck tonight and about 3/4 the way to my destination i noticed i had a ton of smoke following me. I had a full rear tank when i left and when i looked down it was already half gone. By the time i pulled over i was almost empty. Just had it towed home and i have not had a chance to look at it yet, but definitely coming from somewhere under the turbo cover. Hoping it will be obvious when i get a chance to check it out.... Is there a common failure point i should be looking for?
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Old 01-16-2013, 06:13 AM   #2 (permalink)
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Look at the fuel pump, it is right undr the turbo, and look to see if the valley is full of fuel.
If it is, you want to get it all washed out as soon as you can, diesel fuel will eat away at all wires and such.
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Old 01-19-2013, 02:04 PM   #3 (permalink)
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Well, finally got a chance to have a look. Took the fuel filter cap off and it was completely empty. I also noticed alot of dirt and build up on top of the filter. (I just changed it 1000 miles ago and it was very clean in there. ) Once i got the canister removed i discovered a pretty big hole blown out the bottom of it. I cant figure out what would cause this??? What are my options now? I found a new one at rock auto for about 250, which is about what used ones are going for. Is there any way to repair the hole or is new the way to go?

thanks in advance,
dave
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Old 01-19-2013, 02:18 PM   #4 (permalink)
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I'd go with the new one but some have cleaned the bottom of the housing real well and used JB Weld to seal up the hole. It's up to you on what you want to do.
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96 F250 PS XLT 4X4 long box, 5sp,4.10, manual hubs,pyro+boost guages, Dark Toumaline, add a leaf, Dale's TYMAR, and HX hose, downpipe, coolant filter, Luk clutch
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Old 01-19-2013, 02:25 PM   #5 (permalink)
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So is this a common problem on these?

I also found a post titled below at power-stroke nation, any thoughts on that mod?

The "Tightwad mod" Fuel Bowl delete and regulated return for peanuts
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Old 01-19-2013, 02:58 PM   #6 (permalink)
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To do that you would still need to purchase and install a separate fuel filter/water separator onto the fuel lines. Which in time will also leak if not properly maintained.
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Old 01-19-2013, 03:17 PM   #7 (permalink)
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I've got one that I'll let go cheap. Pm me if you are interested.
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1995 F350 CCLB DRW 4X4 XLT 5 speed 63k miles, 6637, EBPV Delete, non-ebpv turbo pedestal, 3" DP, 4" Diamond Eye Turbo back, US gear overdrive, exhaust brake, gauges

Sold: 1997 F250 Supercab 4x4 XLT (California Model) 178k miles 3" DP, 4" Diamond Eye Turbo back, AFE intake, Swamps AD injectors, Beans Fuel System, EBPV Delete, non-ebpv turbo pedestal, International Bellowed Up Pipes, Stancore GPR.
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Old 01-19-2013, 05:22 PM   #8 (permalink)
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Thanks 97, i'll let you know if this Tightwad mod does not work out. (I decided to give it a shot.)
I just finished modifying my regulator and im getting ready to tap it. Picking up a filter assembly tomorrow from tractor supply. We'll see how it goes!
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Old 01-20-2013, 08:00 PM   #9 (permalink)
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Just wanted to give an update, I did the tightwad mod and everything seems to be good to go. Probably cost me about 70 bucks for everything


Here is a pic of the hole in the old bowl.


Pic of modified regulator installed




Pic of filter/separator setup from tractor supply.
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Old 01-21-2013, 10:38 AM   #10 (permalink)
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How many microns is that filter? I ask because the ones I've seen in the tractor supply stores don't filter to a small enough particulate for the PSD. They may work find on a tractor, but I wouldn't install one on my pickup. You should have something in the 5-10 micron range.
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Old 01-21-2013, 05:33 PM   #11 (permalink)
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It has a 10 micron filter
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Old 03-26-2014, 08:50 PM   #12 (permalink)
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Can you tell me how fuel flows through all the "ports" of the fuel regulator and lines in the system? I can see that 's a stock regulator. The bottom solid line on the stock system is that a return? My regulator is leaking, and I'm looking to do a fuel bowl delete and install an aftermarket regulator (mine may have a leak in the actual housing but I can't see it when its hooked up... it looks fine when I take it off, it may be the oring but ford wants 109 dollars for an oring... rather do a delete in that case. Any info would be appreciated
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