2002 Fuel pump line fitting repair | Ford Thunderbird club group 1955-2005 T-Bird models

2002 Fuel pump line fitting repair

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ScooterDog

ScooterDog

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While replacing the passenger-side fuel pump, I broke one of the 90 degree plastic fittings that insert into the pump. A quick search shows this hose is obsolete. Any suggestions how to repair this?

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ScooterDog said:
While replacing the passenger-side fuel pump, I broke one of the 90 degree plastic fittings that insert into the pump. A quick search shows this hose is obsolete. Any suggestions how to repair this?
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Can you post a photo of the part?
 
Hope you solve your problem, I think the reason why your fitting broke is because the old pump is missing the plastic taps that you press that releases the fitting, with out it is almost impossible to release it.
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Maybe carefuly cutting the old plastic pump.
This is how it works, when you insert the fitting and push down it stars to lock in place, then when you press the two tabs it opens the metal clips that are inserted inside to release the fitting and then you can pull it out.
Without those tabs it would be almost impossible to remove the fitting.
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Hot pin question difficult to answer because thee Ford shop manual & shop electrical wiring manual do NOT address the fuel pump motor other than removal/replacement. The electrical info is directed to the Ford Powertrain Control Emission Diagnosis manual which usually very difficult to purchase.
HOWEVER this may help:
F4.17 15A fuse located in the Battery Junction Box is hot uses a Rd/Bu wire which then goes to the Fuel Pump relay in the Battery Junction box uses pin 3 of connector C446. When relay closes power then goes to pin 5 of Connector C446 on a Gn/Rd wire. Then onto the fuel pump motor.
Hope this helps you out.
 
Currently, I’m in the middle of replacing the fuel pump in my 2002. I had a similar issue occur but the white locking ring broke when I was pressing the tabs. Yep, stuck fuel fitting and thought it impossible to remove. Not to be defeated I removed the white locking ring, basically tore it off, and used a pick to remove the orange insert (shown in the picture the previous post). iThe insert is soft and was easy to remove. Once it was gone the fuel line fitting came right out. My goal was to save the fuel line elbow fitting, everything else comes on the new pump. Just thought I would capture this evolution.

In regards to this post, does anyone know where to purchase the ‘stem-barb elbows on the Fuel return line (part number KFL-18? This part is discontinued and the plastic/nylon elbows are hard to find. I want to buy me a few replacements. NAPA/ O’Reillys/Autozone doesn’t have a listing for them.
 
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BEWARE If you damage the right angle fittings on the Fuel pump! So far have not found a replacement
Plenty of Pumps Available from 60 to 300 dollars YET not a single fitting Strange when these were
used on Lincoln and Jaguars. If anyone has a Clue to where these can be sourced It would be appreciated.
 
You are going to need to get this part at a junk yard, or a used dealer of T Bird parts. I have replaced two fuel pumps, and both
times these press to release fittings gave me a hard time. You have to put a little oil in the press fitting, then press release ring
and wiggle and carefully pull up on elbow fitting, it will eventually release, takes time and patience.
 
uncleed said:
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uncleed said:
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You are correct you need to remove the broken fittings and replace them your correct size for the line size barb and the connect to the push in fitting with a elbow then you have the same basic configuration as the original except it’s brass, not sure what your point is once the old broken piece is removed from the fuel line replaced with brass fitting secure it with a barbed fitting clamp it add the proper push fitting with a elbow and you’re all set.
 
I am having serious issues trying to disconnect the two lines to the fuel pump on my 2002 TBird. I replaced the fuel pump with a Delphi FG1340, but cannot for the life of me get the locking ring to screw back onto the tank, and hence it leaks fuel. And now i can't disconnect the two hoses so i can see if my ring is stripped.

Any ideas how to disconnect from the red connectors in the pic below? Or anyone else have issues with screwing the locking ring back on, it seems to only catch on the threads partially and then pop off when i try to tighten.

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To correct information posted above Part # Kfl-18 May or May Not Work For those With broken Elbow Fittings As Depending on Where you Order it from the end fitting rhat inserts into your sending Unit can Differ.

All it is, Is a Simple Non Barbed Elbow Fittings, Find One that Matches inner diameter and outer diameter on the end that inserts into your sending Unit and one similar to size on the other end. You'll have to drill out your old Fitting and Going to Have One Hell of a time Getting the new one in. You can't cut the old supply line because more then likely the line will be to short.
 
Also the Carter Pump Listed above DOES NOT come with the elbow fitting what you see in the photo is simply Plastic Plugs You pull out before connecting the supply lines into the Sending unit


Other Options Would Be Searching 1999-2002 3.0 V6 Jaguars and I'm not Sure What Years Lincoln/Mercury But They All Were Pretty Much Ford Companies and Have interchangeable Parts.
 
Since I cannot get the elbow connectors to release from the fuel pump, anyone have any input on this as a solution:

1) cut the fuel line close to the fuel pump
2) put in a new fuel pump
3) I understand from reading that the OD of the female openings in the fuel pump are 5/16". insert these into the female slots of fuel pump: https://www.amazon.com/gp/product/B07DMSGWF2/?tag=thunderbirdforum-20
4) I read somewhere that the ID of the fuel line (part KFL-18) is 3/8". (can't confirm if this is correct or not, anyone know?). If so, i would need to convert the 5/16" to the 3/8" using this: https://www.amazon.com/gp/product/B08MLNQMFS/?tag=thunderbirdforum-20

Open to any help out there.....
 
pschultzy said:
I am having serious issues trying to disconnect the two lines to the fuel pump on my 2002 TBird. I replaced the fuel pump with a Delphi FG1340, but cannot for the life of me get the locking ring to screw back onto the tank, and hence it leaks fuel. And now i can't disconnect the two hoses so i can see if my ring is stripped.

Any ideas how to disconnect from the red connectors in the pic below? Or anyone else have issues with screwing the locking ring back on, it seems to only catch on the threads partially and then pop off when i try to tighten.

View attachment 31836
Click to expand...
Update: i was able to figure out how to remove the elbow fittings from the inserts. Had to cut the tab you squeeze in (used a wire cutter and popped them off). Then, there is a small ring around the stem, you might be able to use your fingertips but i used a long (12") needle nose that is bent at the end in the shape of an L. I then pressed down hard on the elbow fitting, then pressed the small ring around the stem with the needle nose (moved it around a few times and pressing the small ring in multiple places), then keeping pressure on the small ring, i used another long needle nose to grab the elbow fitting and pulled straight up. What a pain!!!

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