[cmartin]

Customer states: I'm getting really bad fuel economy and lately can smell gas sometimes.


Hmmm. A few random photo's of the joys of working on rusty chevy's. Really not that bad but I laugh every time I watch someone unscrew a fastener or say something silly like, "unclip the quick disconnect".

A quick look showed the vent line was broken, ~10" rusted away and missing. The return line was wet. In a few places. The pressure line was a disaster. Not only is the fuel filter rusted solid to the fittings but moving the lines downstream slightly caused a solid leak.

Whats better than rust and fuel running down your arm, soaking your shirt?

The "quick" disconnect is supposed to contain the spacer and o-ring. A truck to press them back into the plastic fitting is to use a deep 9mm socket. Just be careful and you can usually reuse the pieces.

The plastic fittings were so clogged with rust it was soak with PB Blaster, scrape with a pick. Rinse, repeat and they finally came loose.

I found a good deal on new fittings, filter and nylon line from https://www.inlinetube.com/ . I cut out most of the OG lines but left the section along the transmission. Pulling the front driveshaft, that I bet has never been touched, made it possible to fasten the new lines out of the way and provided much needed room for my big mits.

Not a horrible job, but one that takes commitment. I learned a long time ago to never leave a job stranded in the shop. Worse if its blocking a lift. After some looking and poking I realized I had to cut out the old lines in sections. No going back from there, just methodical work. This job should have happened a few months ago, but now its done. The lines broke with just a touch in several places. Surprised the truck never had a evap code and that it actually ran.

[Trak Ratt]

Life by the water? Looks like something you’d be more likely see closer to the ocean. BTW nice job.

[cmartin]

This was a pretty bad case but unfortunately similar examples are pretty common. If you are in the mid atlantic or other salt spreading area it only takes a few minutes to inspect fuel and brake lines during an oil change. Fluid film or something similar, especially at retainers and fittings is a good idea too.

I can only guess GM saved a few dollars per truck using inferior materials, think about the shareholder value! The newer trucks I've worked on seem to have a different material, I dont know if its any better. Time will tell.

[Eplebnista]

If that truck ever lived in Michigan, that is all you need to know.

[Vicegrip]

Yep, I have 4 chebbys in the work fleet and that is not unusual . Crusty lines are a given but even the good quality replacement line sets are cheap and easy to replace as a one time project. When they START to crust up around the fittings and sharp bends order a complete set and get to it. Not a lot of time to replace when done all together and the sets are cheap in relation to Porsche parts. An entire fuel line set is less than the tax alone on a late model 911 fuel pump.

Magnesium chloride is hard on cars.

[trytryagain]

Better check the brake lines too if you’ve not replaced them already.

[onboost]

Originally Posted by trytryagain

Better check the brake lines too if you’ve not replaced them already.

^ This! They are notorious for rusting away, typically starting as pinholes.