Fuel Filter/seperator drain o-ring replacement...my first write up

[Turbo1Ton]

Okay, I found this post because I have the fuel smell and a drip off of the engine. This is my step-dads truck. He had the leak appear last year about this time and it sealed up after a few hours and he hasn't seen it since then. That is what prompted me to start looking for a solution I changed the o-rings out this evening. Has anyone continued to have a drip after the fact, possibly from residual fuel on the valley still dripping down?

My drip is coming off of the dust cover. There is a little dimple on the very center of the dust cover that it seems like it is dripping out from.

I have fuel all over the valley and then this drip. Does this sound like the same issue? Have others had this drip from the same location? I think I read all but one page of this post. I probably skipped the page that says if your drip is off of the dust cover it is a different issue!

My next course of action is to check/change the WIF sensor o-rings.

Thanks for the help.

Jeff

[78Southwind]

Great post. I'll be changing out the o-rings when I replace the fuel filter.

[Capt79]

Add another one to the list. Mine started to leak this week when the temperature dropped. Checked everywhere to find the O-rings, ended up ordering them through http://www.smallparts.com.Can't wait to change them.

[hit_cb]

just got two new sets off ebay for a total of $4 with shipping got to me in less than a week their viton and their suppose to stand up to just about anything

[Niner1190]

Anyone have a set they want to sell me for cheap? I was thinking about changing my fuel filter so I might as well do this at the same time.

[mrwink]

Thanks for writing this up! I'm gonna get it done tomorrow assuming I can find the o-rings!

I wanted to be able to have the instructions with pictures with me when I do this so I made a pdf of the post with pics. o-ring replacement.pdf Hope it's not out of line to post this!

[Riggodeaux]

With nice weather yesterday, I finally got around to doing this o-ring fix [fortunately, hadn't needed the truck recently ....]. As noted, the process is straightforward, but the space is so cramped that its a pain in the arse to unscrew the T20 torx screws and remove the valve. I couldn't find a 1/4 drive T20 socket closeby, so I ended up using one of those cheap 90 degree angled T20 key [like a hex key]. I don't have real big hands, but it was tough to fit back in there, especially spread-eagled over th engine and reaching down behind the filter. Ended up dropping the key, and one of T20 screws, down into the valley multiple times [requiring a second trip to the local Advance Auto for one of those flexible recovery grippers]. Ended up taking a couple hours, what with the trips to Advance, so be prepared. I had previously installed a drain line on the purge outlet, so I avoided any more diesel mess. As expected, this fixed the leak!

[Motoman]

Wow good reading here.... just turned 103K on the odometer and saw a fuel leak. Glad to see the exact problem explained here. I went to smallparts.com and ordered the following:

ORV-202
1/4
1/2
1/8
0.234
0.005
0.139
0.004
-
$2.20

bag of ten.... 2.20 + 4.19 for shipping to AZ.

Will post up pictures of install when the o-rings get here!

Thanks a bunch for the sticky!

[MIspecial]

Just changed out mine today. I used an adaptor, Spinner, 1/4" male to 3/8" female, that made things alot easier to turn those torx out by hand. Will be tough if you have large hands.
FSD38, Adaptor, Spinner, 1/4" male to 3/8" female

[strokenazi45]

i have a 2002 power stroke and i just had to replace the o-ring my self .they crack and the diesel eats them up .

[joedirt]

been a while since ive been here,...glad its helped a bunch of people

[nbwilliamson]

where can i get replacement bolts for the fuel drain kit i dropped one and cant find it ?

[kwitte]

where to get o-rings:
your local industrial supply, like Welcome to MotionIndustries.com or Applied.com Industrial Bearings, Material Handling, Power Transmission, Fluid Power Products | Applied Industrial Technologies | Applied.com | Applied.com, they will probably have them in stock.

Failing that, go to the one stop shop like McMaster-Carr or MSC Industrial Supply Co. Home Page .... these guys have everything from fasteners to tools to just about any gadget you can think of.

[abamadude]

I have phillips head screws on my drain valve. I don't see where anyone else does. I have a 96. The number 20 torq bit didn't fit lol.

[klhansen]

Originally Posted by abamadude

I have phillips head screws on my drain valve. I don't see where anyone else does. I have a 96. The number 20 torq bit didn't fit lol.

Maybe someone replaced them. The 94-97 fuel bowl I messed with had torx head screws.