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Sable03

Broken Quick Connect Fuel Filter Connector - Now What

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We went to replace the fuel filter on our 2003 Sable and everything was so rusted that the line would not pull off the filter.  Try as we did, the connector broke and now we need to replace.  Has anyone else had to do this and what did you do to repair?   Thanks for the Help.

 

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Dorman makes a nylon repair hose with those ends on them. Most parts stores carry it in the Help! section.

The premise is you can either join the nylon hose together using the provided hose barb in the package and heating the nylon on the repair and vehicle with hot water until it sets (obviously difficult while under the car, but I'm not sure a open flame would be a good idea around fuel), or using a compression type fitting to join the lines together.

Edited by Kodachrome Wolf
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Kodachrome Wolf, thanks for pointing me in the right direction.

Problem fixed with two products - Both compliments of Dorman.  Two important points, there is a rubber hose over the fuel line to protect against chaffing.  Be sure to leave as much of it as you can on the line.  2nd is to make sure the 5/16" Fuel line is fully seated into the Fuel Line Union.   My first attempt I failed to get it fully in and the fitting leaked heavily.  Once I pushed it the rest of the way in, it sealed nicely and worked perfectly.  It might be a good idea to put tape around the line to measure how far in it goes.  It would give you a visual reference to see how far in you have pushed the fuel line.  I would do that if I were doing it again.  That would ensure proper seating into the fittings.  Then just remove the tape once it is installed.

https://shop.advanceautoparts.com/p/dorman-help-nylon-fuel-line-unions-5-16-in.-800-191/10191248-P?searchTerm=800-191
   And
https://shop.advanceautoparts.com/p/dorman-help-5-16-in.-quick-connector-90-degree-w-18-in.-of-5-16-in.-nylon-tube-and-a-union-800-051/16140062-P?searchTerm=800-051

Dorman-Fuel-Line-Repair-Kit-800-051 (Mobile).jpg

Dorman-Fuel-Line-Repair-Kit-800-051-2A.jpg

IMG_6032 (Mobile).jpg

IMG_6041 (Mobile).jpg

IMG_6042 - Copy (Mobile).jpg

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Update ----- It ain't over till it's over.  The Dorman Press Fit Union started to leak after a couple days.  So back under the car for round two.  This time I used the another Dorman product, a Fuel Line Compression Union.  It is designed to be used with the Nylon Fuel line. 

 

Click here to see the Dorman Part - #800-145

I think because the line had a slight arc to it, that the Press Fit coupler couldn't seal fully.  If it is used on a Straight run it would probably work.  But in all honesty, after using the Compression Union, I think it is a better solution.  It wasn't much more work and I have a very good feeling about the quality of the repair.  

I included a photo of the original Filter I removed so you can see what got me into this mess. It had clearly been neglected.  The original fitting broke because it was rusted right onto the filter.  It was really difficult to get off.  If nothing else, this should encourage folks to replace the fuel filter on a regular basis to avoid this from happening.  Especially in the Rust Belt.

 

1 - Old Filter (Large).jpg

2 - Leaking.jpg

3 - 800-145 Compression Union.jpg

4 - 9009861656_431a566864_o (Large) (Large).jpg

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