Fuel Line Fitting: Hairpin or Duck Bill Clip? (’85 F-150 EFI 5l dual tanks)

[Nemesis F150]

I think the 3/8" line and then the right connectors makes it easier. I used this 5/16 In. Steel To 3/8 In. Nylon connector and these 3/8 In. Steel To 3/8 In. Nylon ones. Obviously they aren't 90 degree, but they make them as well.

Thanks for the info Gary.

Based on the diagram "FUEL LINES and RELATED PARTS, 1985 F150/250 - 8 CYL 302 (5.0L) - E.F.I., this is what I came up with for the minimum Dorman connectors to order. All tubing size will be 3/8" and all connectors will be to steel. In the table "S" was used for Straight and "L" for angled.

Notes:

(1) the existing lines from the Reservoir has one angle and one straight, but it is not known what the line size is so will order an extra connector for each line size connection (if that makes sense)

(2) Pump: It is unknown what the terminations are for the exit lines where they attach to something, so nothing counted for the ends. If anyone knows what the ends are please let me know. Otherwise, may use existing line or fix line later.

(3) Rear and Midship Tank connections are assumed to be straight.

(4) Have not checked if there is a "standard pack" quantity available yet.

[Help! I need more learning! Can't get the image to be larger. Started with a numbers file, saved to pdf (because jpg wasn't an option), then saved the pdf file to jpg and "largest". Still can't get image larger.]

[EDIT: Aug 1, 2022 Did a Screen Shot of the spreadsheet then saved it as a *.JPG and posted it. BINGO!

Thanks, Gary. (Learn something new every day!) ]

[Edit #2: noticed that the pdf file didn't have the Rear Tank row included in the spreadsheet. Went back to the file and grabbed the one with that row in it and replaced the mini spreadsheet. ]

[Gary Lewis]

Thanks for the info Gary.

Based on the diagram "FUEL LINES and RELATED PARTS, 1985 F150/250 - 8 CYL 302 (5.0L) - E.F.I., this is what I came up with for the minimum Dorman connectors to order. All tubing size will be 3/8" and all connectors will be to steel. In the table "S" was used for Straight and "L" for angled.

Notes:

(1) the existing lines from the Reservoir has one angle and one straight, but it is not known what the line size is so will order an extra connector for each line size connection (if that makes sense)

(2) Pump: It is unknown what the terminations are for the exit lines where they attach to something, so nothing counted for the ends. If anyone knows what the ends are please let me know. Otherwise, may use existing line or fix line later.

(3) Rear and Midship Tank connections are assumed to be straight.

(4) Have not checked if there is a "standard pack" quantity available yet.

[Help! I need more learning! Can't get the image to be larger. Started with a numbers file, saved to pdf (because jpg wasn't an option), then saved the pdf file to jpg and "largest". Still can't get image larger.]

[EDIT: Aug 1, 2022 Did a Screen Shot of the spreadsheet then saved it as a *.JPG and posted it. BINGO!

Thanks, Gary. (Learn something new every day!) ]

[Edit #2: noticed that the pdf file didn't have the Rear Tank row included in the spreadsheet. Went back to the file and grabbed the one with that row in it and replaced the mini spreadsheet. ]

I think you have it figured out pretty good.

As for picture size, I right-clicked your picture and then clicked Copy Image Address, Clicked Insert Image in the menu above and pasted the address into the "Or copy an image from the internet" field, wiping out the "http://" that's already there.

After clicking Insert Image I added "width="75%" to the code, as shown below - but w/o the "" before and after the code so you can see it.

nabble_img src="2022_85_F-150_EFI_5L_2WD_LWB_Dorman_Connectors_24.jpg" border="0"width="75%"/

But sometimes it is easier to take a screenshot of what you are working with instead of saving the file to one format then another. By taking a screenshot you can capture only the area you want and leave things out you don't want, like the "1" at the bottom. But be careful as Win11 seems to want to save screenshots in png format and they can get large quickly. I prefer jpg.

[Nemesis F150]

I think you have it figured out pretty good.

As for picture size, I right-clicked your picture and then clicked Copy Image Address, Clicked Insert Image in the menu above and pasted the address into the "Or copy an image from the internet" field, wiping out the "http://" that's already there.

After clicking Insert Image I added "width="75%" to the code, as shown below - but w/o the "<" and ">" before and after the code so you can see it.

nabble_img src="2022_85_F-150_EFI_5L_2WD_LWB_Dorman_Connectors_24.jpg" border="0"width="75%"/

But sometimes it is easier to take a screenshot of what you are working with instead of saving the file to one format then another. By taking a screenshot you can capture only the area you want and leave things out you don't want, like the "1" at the bottom. But be careful as Win11 seems to want to save screenshots in png format and they can get large quickly. I prefer jpg.

Quantity take-off

Issue: One of the key, and important, Dorman fuel line parts is not available any longer. This is the Dorman 800-084 Fuel Line Quick Connector That Adapts 5/16 In. Steel To 3/8 In. Nylon Tubing. The web page states:

“Currently unavailable. We don't know when or if this item will be back in stock.”

There is a ripple effect because without this part one cannot use the 3/8-inch tubing so only the 5/16-inch tube can be used. This creates still another problem: It appears the 5/16 tube is not available in lengths longer than 10-feet and the distance from the Rear Tank to the Tank Switch #9189 …. MAY be LONGER than 10 feet. Realize the rig has a 9-foot bed.

What to do? Options:

If the Rear Tank run is longer than 10 feet then (Option #1) two lengths of the line will be needed for that run, plus a barb-to-barb fitting in order to splice the two sections together. Two lengths of 10-feet will probably be needed anyway for the other sections of 5/16 line.

Option #2 may be to relocate the Tank Switch further aft to eliminate the splice. Don't really want to drill through the frame rail or even reconfigure everything. One thing leads to another. Just remembered, there is also the wire harness to the Tank Switch so moving the switch aft may not be plausible option.

Option #3 may be to just use the old 5/16-inch line. After going this far? Ugh!

I’m sure a 25-foot length of 5/16-inch line must be available 'somewhere' but haven’t found it yet on Amazon. It would be helpful to get everything from one place, especially if it is Dorman.

Is Dorman fazing out this system? Or is this another sign of the broken-link supply chain?

Ready, Set, ORDER (?)!

I’m ready to place an order so if anyone has a resource for the 25-ft roll of 5/16-inch Dorman fuel line PLEASE let me know.

(took a year to get this far, so what is another day or two?)

In the meantime I’ll start putting things in the cart so that much is done.

 

[Nemesis F150]

Quantity take-off

Issue: One of the key, and important, Dorman fuel line parts is not available any longer. This is the Dorman 800-084 Fuel Line Quick Connector That Adapts 5/16 In. Steel To 3/8 In. Nylon Tubing. The web page states:

“Currently unavailable. We don't know when or if this item will be back in stock.”

There is a ripple effect because without this part one cannot use the 3/8-inch tubing so only the 5/16-inch tube can be used. This creates still another problem: It appears the 5/16 tube is not available in lengths longer than 10-feet and the distance from the Rear Tank to the Tank Switch #9189 …. MAY be LONGER than 10 feet. Realize the rig has a 9-foot bed.

What to do? Options:

If the Rear Tank run is longer than 10 feet then (Option #1) two lengths of the line will be needed for that run, plus a barb-to-barb fitting in order to splice the two sections together. Two lengths of 10-feet will probably be needed anyway for the other sections of 5/16 line.

Option #2 may be to relocate the Tank Switch further aft to eliminate the splice. Don't really want to drill through the frame rail or even reconfigure everything. One thing leads to another. Just remembered, there is also the wire harness to the Tank Switch so moving the switch aft may not be plausible option.

Option #3 may be to just use the old 5/16-inch line. After going this far? Ugh!

I’m sure a 25-foot length of 5/16-inch line must be available 'somewhere' but haven’t found it yet on Amazon. It would be helpful to get everything from one place, especially if it is Dorman.

Is Dorman fazing out this system? Or is this another sign of the broken-link supply chain?

Ready, Set, ORDER (?)!

I’m ready to place an order so if anyone has a resource for the 25-ft roll of 5/16-inch Dorman fuel line PLEASE let me know.

(took a year to get this far, so what is another day or two?)

In the meantime I’ll start putting things in the cart so that much is done.

Think I found a (1) partial solution with the lack of 5/16 steel > 3/8" connectors AND (2) the 5/16" line problem because only 10-ft lengths are found to be available.

There is a long line run from the Rear Tank to the Fuel Selector VALVE 9189 with both the 5/16" and 3/8" lines.

After looking at the Rear Tank pump/sender unit it was noticed that the 5/16 and 3/8 steel stubs face different directions. Since the two lines run parallel to each other, it appears that a 90º angle 5/16 steel > 3/8 connector can be put there.

Also, the Selector VALVE has both supply and return lines attached to the bottom of the VALVE with 90º angle connectors. Given this condition, with two 5/16 steel > 3/8" connectors this means a 3/8" section of the long 25-ft line can be used for the long return line in lieu of 5/16.

I think this is what I'll go with in the parts order.

[Gary Lewis]

Think I found a (1) partial solution with the lack of 5/16 steel > 3/8" connectors AND (2) the 5/16" line problem because only 10-ft lengths are found to be available.

There is a long line run from the Rear Tank to the Fuel Selector VALVE 9189 with both the 5/16" and 3/8" lines.

After looking at the Rear Tank pump/sender unit it was noticed that the 5/16 and 3/8 steel stubs face different directions. Since the two lines run parallel to each other, it appears that a 90º angle 5/16 steel > 3/8 connector can be put there.

Also, the Selector VALVE has both supply and return lines attached to the bottom of the VALVE with 90º angle connectors. Given this condition, with two 5/16 steel > 3/8" connectors this means a 3/8" section of the long 25-ft line can be used for the long return line in lieu of 5/16.

I think this is what I'll go with in the parts order.

I think you have a reasonable plan.

[Nemesis F150]

I think you have a reasonable plan.

Update August 2: The Dorman connector tool kit arrived today, and the fuel lines with various connectors were ordered today with an ETA by the end of this week.

Progress!

Another step forward.

[ArdWrknTrk]

Update August 2: The Dorman connector tool kit arrived today, and the fuel lines with various connectors were ordered today with an ETA by the end of this week.

Progress!

Another step forward.

Well, that's great news!

Yes, progress is goooood.

[Gary Lewis]

Update August 2: The Dorman connector tool kit arrived today, and the fuel lines with various connectors were ordered today with an ETA by the end of this week.

Progress!

Another step forward.

[Nemesis F150]

In my last post I wrote "Will have to think this over.". That was almost a year ago!

What happened in the meantime? Had to get a lot of outside work done on the house which was a bigger project than I thought it would be. By then, the weather had deteriorated enough that the mechanical work was not weather friendly.

Spring came, April and May were the two wettest months on record, along with cold temperatures. June was boat haulout for bottom paint and then the weather started to improve, but then I had an accident and recovery will take at least a couple months. However, I have found a mechanic that is willing to work with me (not for free) but I have to get some parts.

Parts update: I have both rear and saddle tanks (Spectra) along with their respective Fuel Pump/Sender units, so that much is accomplished.

Do need to get (1) Fuel lines, (2) Dorman Fuel line fittings, (3) Dorman Fuel Line Repair Tool, (4) Heat Shrink for color-coding the lines, (5) and fuel line covers, if need, to replace existing. (6) May need insulation like Gary used in his project if the lines go near the exhaust.

Dorman Fuel Line Repair Tool: Last year the cost for the tool which included an assortment of tool parts, cost $91.72 (via Amazon w/ free freight); when I checked the price using the link today, the cost was $69.96, and that was a surprise as everything else has increased in price. This has just been ordered.

Fuel Line Fittings: I'll do another post about the Fuel Line Fittings as the Shop/Ford Diagram indicates "straight-in" fittings to the fuel filter Reservoir, as opposed to my fuel filter Reservoir that has all angle fittings. I'll explain in another post.

A little update on the Dorman fuel line parts order:

Wednesday afternoon: Ordered the parts from Amazon with ONE order. One of the 12 items had to come from a different Amazon warehouse so at checkout it was stated that the one item would be shipped separately with arrivals on different days (one on Thursday and the other on Friday) unless I wanted everything delivered at one time. The thought was it would save gas and driver time if everything would be shipped together so I opted to keep everything together. Check: ship together.

Lo and behold, there were three emails on Thursday, one for each of the separate shipments. Huh??? Yes, they divided everything into 3 separate shipments. I followed the tracking on them with ETAs of 9 or 10 pm.

Today, Friday, at noon, 2 of the shipments arrived, in TWO separate parcels. The third shipment still has a 10 pm ETA.

Oops: Realize that I forgot to order the colored shrink-wrap for tube identification. No biggie, the two lines from the Rear Tank will be different sizes so there is no way to mix them up. The Mid Tank will be installed later.

Fuel Lines:

Both lines are "Nylon Fuel Line" by "Dorman", but what is interesting is that the cosmetics on the packages are way different. The 3/8" line cosmetics is the same multicolor graphics as on all the fittings; however, the 5/16" package (both packages have a folded cardboard strip with a clear plastic bag) is bright yellow with black writing, P/N 800-074, and a Dorman logo.

Comment about the fuel line stiffness:

One line (5/16 x 10ft) is coiled into a very tight 6.5-in OD coil and the other (3/8-in) into a 9.5-in OD coil. Both lines are VERY STIFF! This is not what I had expected (my first time dealing with this type of line). I anticipate it will be more difficult to do the installation than expected, especially when there are tight bends.

The heat gun (away from any fuel) will likely be my friend. Note: even Marine-Grade fuel lines are much more flexible than these are!

QUESTION: Given that the end of the Nylon tubing must be heated so the barb can be inserted, is that all there is to the connection? or is a hose/line clamp needed?

[Gary Lewis]

A little update on the Dorman fuel line parts order:

Wednesday afternoon: Ordered the parts from Amazon with ONE order. One of the 12 items had to come from a different Amazon warehouse so at checkout it was stated that the one item would be shipped separately with arrivals on different days (one on Thursday and the other on Friday) unless I wanted everything delivered at one time. The thought was it would save gas and driver time if everything would be shipped together so I opted to keep everything together. Check: ship together.

Lo and behold, there were three emails on Thursday, one for each of the separate shipments. Huh??? Yes, they divided everything into 3 separate shipments. I followed the tracking on them with ETAs of 9 or 10 pm.

Today, Friday, at noon, 2 of the shipments arrived, in TWO separate parcels. The third shipment still has a 10 pm ETA.

Oops: Realize that I forgot to order the colored shrink-wrap for tube identification. No biggie, the two lines from the Rear Tank will be different sizes so there is no way to mix them up. The Mid Tank will be installed later.

Fuel Lines:

Both lines are "Nylon Fuel Line" by "Dorman", but what is interesting is that the cosmetics on the packages are way different. The 3/8" line cosmetics is the same multicolor graphics as on all the fittings; however, the 5/16" package (both packages have a folded cardboard strip with a clear plastic bag) is bright yellow with black writing, P/N 800-074, and a Dorman logo.

Comment about the fuel line stiffness:

One line (5/16 x 10ft) is coiled into a very tight 6.5-in OD coil and the other (3/8-in) into a 9.5-in OD coil. Both lines are VERY STIFF! This is not what I had expected (my first time dealing with this type of line). I anticipate it will be more difficult to do the installation than expected, especially when there are tight bends.

The heat gun (away from any fuel) will likely be my friend. Note: even Marine-Grade fuel lines are much more flexible than these are!

QUESTION: Given that the end of the Nylon tubing must be heated so the barb can be inserted, is that all there is to the connection? or is a hose/line clamp needed?

It isn't necessary to heat the end of the tubing to insert the barb. It just helps get the things started. But there is no clamp needed, it won't leak.

And yes, the lines are stiff. Hence the heat to soften them a bit. Again, it isn't needed but just helpful.

If the line is rolled up tightly I think I'd unroll it a day or so before trying to install it. And it doesn't stretch, so don't cut it too short.

As for Amazon's shipping, I've seen the same thing and I've given up on trying to help them. I think they could save a ton of money and a lot of fuel if they would sort their logistics out.