Bypassing sending unit - Dodge Cummins Diesel Forum
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post #1 of 9 (permalink) Old 04-15-2019, 06:56 PM Thread Starter
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Bypassing sending unit

Howís it going everyone. I feel like Iím always on here at this point trying to find solutions to issues. Anyways, I recently had an issue with getting air in my fuel. Iíve been searching around for a replacement fuel line and a replacement sending unit since Iíve already dropped my tank and why not go ahead and do it while Iím in there. However Iíve ran into 2 issues, I canít find a fuel line, and I canít find a sending unit. I was wondering if thereís an easy way to bypass the sending unit and run a sump on the bottom of the tank without running an air dog or fass, I have the HVLP lift pump on my truck and would like to keep it. Is there a way to get a sump to work with the lift pump I have on it while using the stock fittings? Or is there a way to replace those fittings? Any help would be awesome


1993 12V W250, POD injectors, AFC Delete, 14 psi piston lift pump, 60mm inducer, 16cm housing, 3200 GSK, glowshift 3 pillar gauges
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post #2 of 9 (permalink) Old 04-15-2019, 07:55 PM
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For fuel line just get some 3/8 steel brake line for the supply and 5/16 for the return. It's no big deal for a sump just cut the hole in the bottom and run a line to the steel supply line and connect to the LP. Use rubber fuel line to connect the steel line to the LP and Sump.

Sounds like your over thinking it.

84 K5 Blazer 97 12v, 47re with E-TransControl, Dodge Dana 60 with free spin hubs, Dana 70, B&M Mega shifter

96 F350 SC dually zf5, 4x4, 92 Cummins, THD 5x12's, THD fuel pin, THD HVLP with adjustable fuel pressure mod, WM, h1c 60/60/12cm WG wired
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post #3 of 9 (permalink) Old 04-15-2019, 08:02 PM Thread Starter
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Originally Posted by 9297oldram View Post
For fuel line just get some 3/8 steel brake line for the supply and 5/16 for the return. It's no big deal for a sump just cut the hole in the bottom and run a line to the steel supply line and connect to the LP. Use rubber fuel line to connect the steel line to the LP and Sump.

Sounds like your over thinking it.
Wow, I way overthought it. Been a long day I guess. Thank you for the help! Does anyone have any recommendations for a sump?

1993 12V W250, POD injectors, AFC Delete, 14 psi piston lift pump, 60mm inducer, 16cm housing, 3200 GSK, glowshift 3 pillar gauges
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post #4 of 9 (permalink) Old 04-15-2019, 08:06 PM
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Wow, I way overthought it. Been a long day I guess. Thank you for the help! Does anyone have any recommendations for a sump?
I bought one from THD but if you was to Google fuel tank sumps they are available about anywhere. Just remember buy cheap and you'll get cheap.

84 K5 Blazer 97 12v, 47re with E-TransControl, Dodge Dana 60 with free spin hubs, Dana 70, B&M Mega shifter

96 F350 SC dually zf5, 4x4, 92 Cummins, THD 5x12's, THD fuel pin, THD HVLP with adjustable fuel pressure mod, WM, h1c 60/60/12cm WG wired
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post #5 of 9 (permalink) Old 04-15-2019, 10:31 PM
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i just got done installing a big line kit thru the stock sending unit. followed a members detailed instructions and went very easy.
i just ran rubber lines up front

1992 w250 cc, 5spd "in progress"
98 12v cclb 5spd 4wd
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post #6 of 9 (permalink) Old 04-15-2019, 11:14 PM
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i just got done installing a big line kit thru the stock sending unit. followed a members detailed instructions and went very easy.
i just ran rubber lines up front
Running through the stock sending unit makes a big line kit pointless.... unless you put a larger draw straw in the unit.
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post #7 of 9 (permalink) Old 04-15-2019, 11:33 PM
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Quote:
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Quote:
Originally Posted by nick05 View Post
i just got done installing a big line kit thru the stock sending unit. followed a members detailed instructions and went very easy.
i just ran rubber lines up front
Running through the stock sending unit makes a big line kit pointless.... unless you put a larger draw straw in the unit.
yes from the new bulkhead fitting i ran a 3/8 line inside sending unit down to the white adapter (gasser fuel pump) and also drilled that out larger.

1992 w250 cc, 5spd "in progress"
98 12v cclb 5spd 4wd
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post #8 of 9 (permalink) Old 04-16-2019, 12:03 AM
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for big trucks when we need to add an extra sump (we run 4 fuel tanks on my Petes as I absolutally will not purchase or allow one of my drivers to purchase a single drop of fuel in California, New york, Maryland plus we do oversize loads so ..) I just take a 90 degree elbow (in our case a 1" one for your application a7/16 or 1/2" would be good) one side threaded the other side a nipple, slide a thick washer over the threaded side (this will be your "flange") braze washer in place press a 1" long steel 3/8" tube into the inside of the threaded section (or larger tube if ya used a larger fitting) braze this into place it can be soldered instead (this will keep ya from pulling fuel from the bottom of the tank where the water and debris will collect) drill hole in bottom of tank opposide the stock sending unit so ya can use a socket with a small earth magnet inside it to hold the nut (super glue a large washer to the nut in advance same size as the one ya brazed onto the fitting) use a socket extension and a deep well socket (with magnet inside) to place the nut over the sump fitting... tighten and your done... if ya want (but shouldn't need on poly Dodge tank) add a nylon or nitril washer to act as a gasket between the outside fitting and the tank.....

the only difference with the big trucks is I TIG weld a threaded bung into the bottom of the tank to thread the fitting into, I have used the above method many times for offroad fuel tanks for 4x4s I usually use two sumps one with a 3" stand pipe and a second with a 1" stand pipe ya race on the 3" sump the short one is reserve supply just flip a fuel switch to go from one to the other...
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post #9 of 9 (permalink) Old 04-16-2019, 12:45 AM
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A couple of years ago my 92 W250 was getting air in the fuel supply line and I ended up installing one of these and have had no issues since.

For standard tank modules with original equipment quick connects 94-04

1990 D250, G360, w/303K on the clock.
1992 W250, Auto, w/245k on the clock.
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