My Regulated Return
Attached is a photo, taken this morning when I checked the oil, of my Regulated Return System. I installed it when the truck was relatively new after I tried a lot of other things to quiet it down some. It used to look a lot cleaner before I allowed a protective layer of grime as rust preventative
. For noise reduction the RR worked better than the other things I tried. It had a clank clank clank that sounded like a coffee can with and angry chipmunk in it armed with a ball peen hammer. Truck ran well and lost the sound when driving but it just didn't fit my sense of order to sit there idling and hearing that.
Back then not all that many people had Regulated Returns, much of it was custom made. Now there are many commercial product offerings and some changes from that experimental era. One of which is that newer RR systems almost all have steel braided lines, mine had hose on push lock connections. That held up well for about 5 years then I had to replace the hoses, surprised I didn't have a any leaks as bad as they were cracked. I went back with hose but did a better job of insulating them. Probably due for a proactive hose change, when they start to get stiff that's when they crack the first ply, wait too long and the internal ply goes. So I give them the flex test occasionally. Takes me about an hour to change the hose parts. It is not regular fuel 30 series hose. Likely if you do a RR you buy a kit and it will have braided hose and never have to concern yourself with changing them. But that's one reason the RR systems you buy cost more than mine did.
In the photo one can see the hose on the PS front of the head going to the left side of the regulator and the hose on the DS head rear position goes to the right side of the regulator. Combined with the stock fuel line hook ups this produces a full flow circuit through both heads, no more deadhead air trap. The hose coming out of the bottom of the regulator goes from the regulator to the existing return to tank line, through a cooler on the frame rail before tank and back into the tank. This is one of the mods I was always glad I did, it actually did what I needed it to get rid of that knocking, which I believe was related to entrained air in the fuel trapped in the dead end fuel rails. I did another mod, pulled the LL injector in # 8 and replaced it with an AD injector and it didn't do anything, still mad chipmunk. That cost me more money and busted knuckles and didn't do anything mechanically significant.
Before anyone points out that my waste gate controller is effectively disconnected I know that, that is the way I run it. I just get my foot out of it at > 15 PSI by my boost gage. Since I don't pull my job trailer around now it is pretty rare for me WOT for anything.
Truck is a dependable work horse, runs better than when it was brand new in April 2002.
2002 F250 7.3L PSD, bought new now at 226K miles, 4R100 Auto, Crew Cab, Short Bed, ITP Regulated Fuel Return system, ITP head to head SS oil cross over, Hutch in tank mod
Harpoon de tank vent, DIESELSITE Dahl 100 Pre-Pump Fuel Filter, DIESELSITE Return Fuel Line Cooler, DIESELSITE Engine Coolant Filter, DIESELSITE Auxilliary Transmission Cooler, DIESELSITE Gage Package, Pyro, Trans & Boost, Extreme Diesel AD injectors, Ford AIS Air Filter System, BTM straight through muffler, Moog Ball Joints, Rancho Shocks, Rotella ELC Coolant ,Stock Engine Program
Modified for I-Pod Connection
We b playing Scotland The Brave to Jimmy Hendrix
Last edited by Oneof6; 10-09-2018 at 11:30 AM.