Fuel line replacement question - Dodge Durango Forum - Forums and Owners Club!
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  #1  
Old 07-25-2017, 01:03 PM
ronsak ronsak is offline
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Default Fuel line replacement question

My '01 R/T just developed a big leak in the fuel line connecting the passenger side fuel rail to the driver side rail. Don't have time to really search the forum until later tonight but would like to hear from anyone if it's an easy fix for a home mechanic.
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Old 07-25-2017, 01:19 PM
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Sounds like you may need a fuel rail. I'm not sure exactly what you have but I assume you have two rails that the injectors are mounted to and a crossover line. If it's leaking probably need to get the whole assembly.
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Old 07-26-2017, 06:28 AM
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As far as I know....you would have to replace the fuel rail that has the cross over line. You mite be able to jerryrig a line but would not advise that for safety.
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Old 07-31-2017, 10:42 AM
ronsak ronsak is offline
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Replacement fuel rail assemblies are difficult to find on line: best price is about $400. I haven't had a chance to check out the salvage yards yet, maybe this week: the 5.9l is a rare find. I have a very good repair shop who said they would look at it and have replaced the connecting fuel line in other cars. I'll update as things progress.
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Old 08-07-2017, 10:01 PM
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Found a injector rail in pretty good shape at the salvage yard off of a 2000 D Magnum (couldn't tell if it was a 5.9l engine or a 5.7l just by looking at it. Parts guy at the local Dodge dealership looked up the parts numbers and the same fuel injector rail is used for both). Removing was made easier by cutting surrounding throttle cables, fuel line going to the rail, removing nearby vacuum lines (throttle body and air intake were already gone). Also didn't need the injectors themselves so I just popped off all the retaining clips and pulled the rail off (made it a lot easier, some the injectors did not want to come out).

In the meantime, took off the existing hose between my D's rails: looks like some animal chewed through so it wasn't a hose failure. Features of the stock hose: 1/4" inside diameter. The inner hose is a hard plastic tube surrounded by a larger rubber hose. The ends plug into a pressure fit connector with two large ridges: the ends of the plastic tubing had expansions that fit onto the ridges (don't know if they were designed that way for a secure fit or were like that after being attached many years). I replaced the line with 1/4" fuel injector line from Advanced Auto Parts (burst pressure rating of 900psi) and secured with fuel injector hose clamps. Seems to be working fine for now for.

I'll have to replace the battery before I go for a drive and report back. I'll save the salvage rail for now in case I run into any problems down the road.
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Old 08-08-2017, 04:33 PM
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Good deal, glad you found a good used one.
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Old 08-10-2017, 01:26 PM
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Forgot to add: I was charged $17 for the fuel injector assembly + $2 admission fee to the salvage yard + couple of hours of my time = total cost. About $10 for the replacement fuel injector hose and clamps at Advanced Auto Parts.
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