Replacing fuel line in gas tanks

Keith Littlepage · Jan 4, 2019

I've replaced several fuel lines in outdoor power equipment and have yet to find an easy way on getting it done. Can some master mechanics please share your techniques with me so I can accomplish this task easier than I seem to be doing it?

Dub11 · Jan 4, 2019

I want no master but I've had this little thing help me out a time or 2.

It came in some kit from Home Depot

blacksmith · Jan 4, 2019

I haven't found an easy way either. I have two carb screwdrivers that the ends are grounded blunt and rounded (so they don't puncture the line) and work it in gently. This is what I do for chainsaws.

Not sure if that's the right way I am no master but it works for ne and I've never had an issue. I'd be interested in how other people preform this task so maybe I can find an easier way myself!

blacksmith · Jan 4, 2019

Dub11 said:
I want no master but I've had this little thing help me out a time or 2.View attachment 157977
It came in some kit from Home Depot

Humm? I can't figure out how that works?

stretch5881 · Jan 4, 2019

Curved forceps.

Dub11 · Jan 4, 2019

blacksmith said:
Humm? I can't figure out how that works?

Feed it through the hole in the tank and have it come out the filler hole. Cut your line with about a 45 degree angle and then hook it on to the wire and pull it through. Make sure to have a little lube on it.

blacksmith · Jan 4, 2019

Dub11 said:
Feed it through the hole in the tank and have it come out the filler hole. Cut your line with about a 45 degree angle and then hook it on to the wire and pull it through. Make sure to have a little lube on it.

Ok I gotcha now. Cool idea!

Dub11 · Jan 4, 2019

blacksmith said:
Ok I gotcha now. Cool idea!

It's just a key ring and a hard thin peice of wire.

huskihl · Jan 4, 2019

On a saw that uses regular fuel line, I cut the end on a 1/2" taper. Push the pointed end through the hole and pull it through with forceps. On a stihl, smear some grease on the line by the grommet, push it down through the hole, pull it down with forceps through the fill hole while helping the grommet with a small screwdriver

Keith Littlepage · Jan 5, 2019

blacksmith said:
Humm? I can't figure out how that works?

I can't either. How do you fasten the fuel line to the wire?

Dub11 · Jan 5, 2019

So pretend the loop in my hand would be the key ring part and the rest is the hard wire.

Snake it down through the tank and have it come out the filler hole.

I left the puller snake thing in my car. So I had to make do with trimmer string.

huskihl · Jan 5, 2019

Keith Littlepage said:
I can't either. How do you fasten the fuel line to the wire?

You don't fasten it. The wire is stiffer and makes a track for the fuel line to ride on up through the hole

Dub11 · Jan 5, 2019

huskihl said:
You don't fasten it. The wire is stiffer and makes a track for the fuel line to ride on up through the hole

I've had to hook a few lines before.

May not be the most efficient way since you end up wasting some line cutting and puncturing it. But it helps on dumb stuff like blowers and trimmers.

Keith Littlepage · Jan 5, 2019

If you don't fasten the fuel line to the wire why would you need to run the wire in the tank at all. I thought you would fasten it somehow and then use the wire to pull it up thru the hole in the gas tank.Since the fuel line fits the hole so snug I figured you use the wire to pull it up from the tank hole.

AVB · Jan 5, 2019

What I use is tag wire fed into the tank and out the opening. Then attach it the the fuel line that a good taper cut on it. Then you pull everything back through the tank hole. Sometimes depending the line size you might only get the taper initially out the hole. That's where a pair hemostats comes in handy to get a better grip on the line to finish pulling it through as the tag wire will tear out at times.

And you would probably need a sharper taper than I have here in this image but this should give you a good idea of what I use to do most handheld tanks.

Dub11 · Jan 5, 2019

AVB said:
What I use is tag wire fed into the tank and out the opening. Then attach it the the fuel line that a good taper cut on it. Then you pull everything back through the tank hole. Sometimes depending the line size you might only get the taper initially out the hole. That's where a pair hemostats comes in handy to get a better grip on the line to finish pulling it through as the tag wire will tear out at times.

And you would probably need a sharper taper than I have here in this image but this should give you a good idea of what I use to do most handheld tanks.

That's what I'm talking about.
That wire I use you would not be able to twist up.

Keith Littlepage · Jan 5, 2019

Thanks AVB; that's what I was needing to see. I believe that procedure would work pretty good. Again Thanks to all who replied.

CR888 · Jan 5, 2019

45° curved long forceps style pliers are handy. Sometime I tie some string around the fuel line tip and pull it through. A smear of 2T oil keeps things slippery.

Stump Shot · Jan 5, 2019

Here's a few of the tools I use to wrestle fuel lines with. Not a lot of money involved to git er Dunn.

AVB · Jan 5, 2019

Hmmm Stump Shot, I didn't know 15 min or less was much of wrestle. Takes me longer to do the paperwork and talk with the customer. I do about 95% with the tag wire trick. Of course there are those problem versions of fuel line mounts where you got get a grommet in place or those with a two piece line setup where you attach the line to a fitting inside the tank but I don't see many of those here. I use those hook tools only to get the fuel filter out so I can check it.

The method I use only requires a precut fuel line with a little extra for the taper. Pulling the line through is easier than pushing as the line stretches so it become smaller in diameter temporarily less you over stretch it.

Replacing fuel line in gas tanks

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