Ouch!!!!

[james8719]

I started my install, last week. I decided to start with the tank and module mount, so I could still use the truck before I started under the hood. The tank and module mounting went without a hiccup. Today I started under the hood. The rear passenger fuel line connector was not lined up for the wrench, so I modified a ratchet wrench to get to it and it worked like a charm. Now the OUCH! I put a 9/16" socket on the engine part of the fuel line fitting and it SNAPPED! The fitting broke off flush. Now what? I guess I am going to have to tow it to a garage and have the broken piece removed. I don't see anyway of getting it out without removing the head. It"s too tight of a spot to get an easy out in there.
Am I just going to have to take it to a garage or does anyone have any suggestions? I really need some help here.

[Elvia]

So, did the fuel line break? or the part in the head? If the part in the head, You might be able to use a bolt romover to back it out. Granted, it will not be easy because there is not that much room to hammer it in. At least its not on the drivers side, then you'd have a problem.
Sorry to hear about this
Good Luck

[tacit_k]

I started my install, last week. I decided to start with the tank and module mount, so I could still use the truck before I started under the hood. The tank and module mounting went without a hiccup. Today I started under the hood. The rear passenger fuel line connector was not lined up for the wrench, so I modified a ratchet wrench to get to it and it worked like a charm. Now the OUCH! I put a 9/16" socket on the engine part of the fuel line fitting and it SNAPPED! The fitting broke off flush. Now what? I guess I am going to have to tow it to a garage and have the broken piece removed. I don't see anyway of getting it out without removing the head. It"s too tight of a spot to get an easy out in there.
Am I just going to have to take it to a garage or does anyone have any suggestions? I really need some help here.

I would be concerned about metal fragments dropping into the fuel rail. About the only thing I can think of short of pulling the head is to be very careful and use a needle grease fitting on a grease gun to put some grease behind the fitting, use an easy out to remove the fitting, then hook up the WVO side of the head and run some vo through the head to push out the grease and any fragments that fell inside, out.

I know is does not seem like a lot of room to work but I am pretty certain it can be done.

[Elvia]

QUOTE then hook up the WVO side of the head and run some vo through the head to push out the grease and any fragments that fell inside, out.

I know is does not seem like a lot of room to work but I am pretty certain it can be done.[/QUOTE]

I think maybe you would push diesel through the head. to push vo, you would have to run the engine to operating temp. Take the fitting out and turning the engine over abit at a time to push diesel through the fitting. You could even have some turning the engine over while you are taking the fitting out. Either way, good luck

[Fordnut74]

James- BE VERY CAREFULL from this point forward. You are the first to break a factory fitting off in the head but we have had one guy do that to our old brass check valves.(we now use stainless). And that guy also used an easy out and wound up cracking hte head along the fule port seam. If you remove your exhaust downpipe, and the turbo you should be able to get a straight shot at the broken fitting and remove it without have to have the head removed. Once you do get that removed, remember you will need a replacmement piece to maek our system work as designed. good luck and let us know how it comes out.

[tacit_k]

James- BE VERY CAREFULL from this point forward. You are the first to break a factory fitting off in the head but we have had one guy do that to our old brass check valves.(we now use stainless). And that guy also used an easy out and wound up cracking hte head along the fule port seam. If you remove your exhaust downpipe, and the turbo you should be able to get a straight shot at the broken fitting and remove it without have to have the head removed. Once you do get that removed, remember you will need a replacmement piece to maek our system work as designed. good luck and let us know how it comes out.

Hey and while you are at it you can replace the o-rings on the turbo, and I would consider drilling and tapping the exhaust for an egt gauge if you don't have one. And just plug the hole till you are ready.

I think maybe you would push diesel through the head. to push vo, you would have to run the engine to operating temp. Take the fitting out and turning the engine over abit at a time to push diesel through the fitting. You could even have some turning the engine over while you are taking the fitting out. Either way, good luck

Actually I was thinking of putting it in forced WVO mode. (switch down)

[james8719]

Thanks for the responses. I tried several times throughout the day[saturday] to get at the broken piece. My big ole meat hooks could just not manipulate the ez out into position. I was going to remove the turbo and downpipe and decided to relax the rest of the day[frustration level getting to high!] I may try removing the turbo and downpipe today[Sunday]. Since I am the first to break the factory fitting, i'll probably be the second to crack the head! I may just take it to a garage this week, before I cause more damage.

[Elvia]

I know what you mean about meat hooks. I have a couple.

[greasyX]

easier out

What about Jb weld(two part epoxy)on a drill bit.The bit should be one MM smaller then hole ,apply epoxy to bit ,insert bit in the hole ,let cure ,then use a right angle drill on low speed(cordless will be easiest).This should be easier then a easy out in tight quarters.I learned this doing a exhaust donut gasket on a diesel VW!!!Good Luck,Don't worry about the meat hooks we all have them ,but some won't admit it..........grease out

[triplemoutdoors]

James its easy for us to arm chair quarterback this thing...I think you are making the right choice take it to the garage and let them deal with it. Good luck.

[tacit_k]

James its easy for us to arm chair quarterback this thing...I think you are making the right choice take it to the garage and let them deal with it. Good luck.

Agree! absolutely not our call.

[james8719]

I had my truck hauled to the local Ford Garage today. Hopefully they will get to it tommorow. I will update later.

[stroker]

please dont bring that to my garage. Or if you do let me know so i can call in sick. That is a very tight spot. nothing fun about the install on that passenger rear.

[Jack_Toepfer]

I've never seen a drillbit stronger than a fitting. The bits always fail first.

Not a bad idea though.

Let the dealership deal with it. You'll be able to make up that cost burnin' oil.

[Elvia]

Hope it doesn't affect your wallet too bad.