Leaking return caps

vegas39

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Good morning all. Just curios if anyone is having return line issues and how long you're getting out of a set of O rings. I replaced my return line system 4 years ago along with my injection pump and injectors, that was at 164,000 miles. I now have 202,000 miles and every return cap is ******* out fuel. Seems to me like we should be getting better than that outa these. Is it the fuel we're getting nowadays?
 

TNBrett

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Not all O-rings are created equal, neither are all return caps. If the caps look ok try replacing the O-rings with Viton ones. Do a search on here for the size as it’s been mentioned several times before and I can’t remember off the top of my head.
 

Big Bart

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Some have suggested the braided hose did not last many years either. As TNBrett mentioned members seem to like the Vito ones. Might just be time to by a new kit and upgrade the o-rings.
 

lakesurfer

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Assuming @typ4 is still kicking, I bought my last cap, hose, & o-ring kit from him and it has been great. Also, consider using the "Zicam Bottle Cap" method when installing the o-rings to minimize nicking them. Procedure is in the tech stickies.
 

Old Goat

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I know from McMaster-Carr you can buy Viton "O" Rings
in bags of 50 for around $8. size 111.

You don`t always have buy a whole new kit.
Last time I changed the return hose, I bought
rubber hose from O`Reillys. Cut to size, used the
spring clamps, and new O Rings. Be sure to replace
each side as an assembly.

If using rubber hose off a roll, it wants to stay the
way it was rolled. I put one section curved one way
and the next the other way to keep it straight. Worked
good and no leaks the past few years.

Goat
 

vegas39

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Ok, thanks for the info. Yeah, I tried using the braided line and it leaked right off the bat. I switched to rubber hose and it's been fine but like I mentioned, all the caps are leaking. I'll see about getting the Viton O rings for it and tear into it.
 

The_Josh_Bear

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Ok, thanks for the info. Yeah, I tried using the braided line and it leaked right off the bat. I switched to rubber hose and it's been fine but like I mentioned, all the caps are leaking. I'll see about getting the Viton O rings for it and tear into it.
One of the best tips is to lube the o-rings well. Grease works great and doesn't hurt to mix with the diesel. This is of course with Viton. My set from Russ @typ4 is going on 7 years or longer, did at least two kits before getting the good stuff from Russ.
 

Cubey

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One of the best tips is to lube the o-rings well. Grease works great and doesn't hurt to mix with the diesel. This is of course with Viton. My set from Russ @typ4 is going on 7 years or longer, did at least two kits before getting the good stuff from Russ.

I used cheap petroleum jelly on the o-rings for both my F250 and RV and both have held up fine for 3-5 years so far. Being more tacky, you're not as likely to drop the o-ring from being so slippery like with grease.
 

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