7.3 fuel return woes

[Idaho Outlaw]

I have a 93 7.3L IDI. I have had the truck 7 years and have replaced the fuel return lines,fittings,caps, and seals twice. Both times I started to develop fuel leaks within a few months. Is this just something I have to just continue to fight. First fuel return kit was one ufrf ebay, The second kit was from IH. Is there a better kit, updated parts, tricks, etc?

 

[6.9poweredscout]

Typ4 has a good kit he sells.

 

[ADV]

Something good like a billet aluminum return line cap?

 

[Mulochico]

ditto on the type4 kit. Great value and quality

 

[riotwarrior]

H there was a guy who was machining some brass ones, but those where very expensive and he didn't go far with them sadly and as hard as I have tried he just does not respond to PM's

 

[franklin2]

I am glad I kept and used the original caps when I did my truck several years ago.

I know little things like this can be aggravating, but it's not rocket science. I would get another kit, or another set of o-rings(tractor supply has them in their hydraulic section) and carefully take the old ones apart. Look the o-rings over carefully and see if they show signs of being damaged. Look inside the caps and see if they look rough or out-of-round. The o-ring simply seals against the injector and the cap, whatever is causing them to leak should be obvious.