Excess fuel coming out of my front tank

Tiny
JDPETERSON83
  • MEMBER
  • 1996 FORD F-250
  • 7.5L
  • V8
  • 4WD
  • AUTOMATIC
  • 135,000 MILES
The sending unit on the front tank is out, always reading zero fuel. So as a result, I always run off my rear tank. No matter what the conditions are, I almost always have fuel seeping out of my filler neck/fuel door on the front tank. To test it, I filled the front tank and drove on it for about 150 miles to run the fuel level down to about 1/2 capacity. Then I switched to my rear tank and have driven on it since then, filling the rear tank up twice since. No matter what, fuel still seeps out of the front tank filler neck. I have come to the conclusion that a) fuel from my rear tank is being pumped to the front tank or b) the return line is only feeding back into the front tank, which means I have a bad shuttle selector valve on the rear tank FDM (I think). I just can't understand how so much gas has been fed into my front tank if it is the return line to where it is overflowing. I need some professional advice please. Thank you!
Tuesday, August 31st, 2021 AT 11:37 AM

3 Replies

Tiny
KASEKENNY
  • MECHANIC
  • 18,907 POSTS
I think you are exactly correct that the issue is in the return line valve that is only returning fuel to the front tank.

The tanks are spliced together in both the supply and return lines. Take a look at the diagram below.

If you are getting proper fuel pressure from the rear tank but the front tank is filling when you are running off the rear tank but the rear tank does not fill when you run off the front tank then that means the valve is not switching the return line when you switch tanks.

https://www.2carpros.com/articles/how-to-check-fuel-system-pressure-and-regulator

Please let us know what you find when you fix this because I think you nailed it.

Thanks
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Wednesday, September 1st, 2021 AT 6:03 PM
Tiny
JDPETERSON83
  • MEMBER
  • 5 POSTS
It was 100% the valve within the front fuel pump as suspected. I took the bed off, and replaced the rear tank since the original has exterior corrosion. I swapped the original pump into the new rear tank since it ran great on that pump. I put a new pump in the front tank, and I'll tell you, that front pump was on its last leg. The strainer was trashed, the float was barely attached to the pump, and there was barely any pressure coming from it. After performing some other planned maintenance to the driveline and rear end, I put it all back together and it runs perfectly, no fuel spillage, etc.
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Tuesday, November 30th, 2021 AT 11:10 AM
Tiny
KASEKENNY
  • MECHANIC
  • 18,907 POSTS
That is great news, and thanks for coming back to confirm that is what the issue was.

This is a great post, and will surely help others that have this similar issue. Thanks for using 2CarPros.
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Tuesday, November 30th, 2021 AT 2:03 PM

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