2000 TJ Fuel Line Fittings

[bbaudoin1981]

I purchased a new set of hard fuel lines for the TJ back in September 2025 from SS Tubes (Fine Lines). Just got around to looking into getting everything changed.
The original hard line and soft line (hose) from the tank were cut and a rubber hose placed in between and secured with hose clamps. A lot of research later, decided to go the route of replacing the hard lines and replacing the fuel tank hose as well as the hose up to the fuel rail.
The russell EFI fittings purchased do not fit the 5/16 hardline. They bottom out and do not come anywhere close to securing in the plastic retainer.

SS Tubes (Fine Lines) Part Number WGL0356ASS
Russell Stainless Steel Fuel Hose Part Number 651111
Russell Fuel Rail Fitting Part Number 640850 - 3/8 in. x -6 AN
Russell Fuel Rail Fitting Part Number 640860 - 5/16 in x -6 AN

Am I missing something? Why would these fittings bottom out and not fit?

 

[macleanflood]

I wrote up a resources post about how to make a new fuel line. Can't find it. Let me keep looking.

-Mac

 

[bbaudoin1981]

I wrote up a resources post about how to make a new fuel line. Can't find it. Let me keep looking.

-Mac

That would be great. As mentioned before previous owner cut the fuel hose from the tank to the hard line. I am trying to replace the entire fuel line from the tank to the fuel rail. A previous thread I found said the Russell fittings in the pictures I provided would work, but they bottom out way before they even come close to the retainer clip.
I am trying to replace the hose from the tank to the hard line. I was going to use the Russell 651111 hose and use these fittings to do so.
Also want to replace on the fuel rail side also.
I contacted SS tubes and they called this morning. They said they have never seen the fittings that I was trying to use. They mentioned a different EFI fitting with O Rings inside and a threaded retainer. I purchased some this morning so waiting for them to come in and will see if I have any more success with those.
Not sure if I am doing something wrong or if the hard line I purchased is just not correct.
For reference my TJ is the 4.0

 

[macleanflood]

Covered some of it n my build thread:

Thread 'Operation Phoenix'

Jun 28, 2023

My wife and I left Fall Creek OR Friday morning headed to the three rivers area in Idaho where the Sellway, Lochsa and Clearwater converge to meet family and cast my 35 yr old sister's ashes into the river.

We decided to take a longer slower route and hit the OOHVA route 5-3...our missing link from our disasterous trip last summer when the rear end grenaded on my 97 Wrangler and we switched to our 2012 JK. It's all on YouTube.

We started in Seneca and camped out a few map pages in on a beautiful creek and meadow enjoying our new Tuff Stuff Trailhead rooftop tent (thankfully mounted to my...

• macleanflood
• Replies: 899
• Forum: TJ Build Threads & Member's Rides

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• 
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You basically need three Dorman parts and a caulk gun to press them together.

3/8 to 5/16 for the tank side:

https://www.amazon.com/gp/aw/d/B000E35WJW?tag=wranglerorg-20

5/16 to 5/16 for the line side:

https://www.amazon.com/Dorman-800-080-5-Fuel-Line-Connector/dp/B00A19LHXE?tag=wranglerorg-20

5/16 nylon fuel line:

https://www.amazon.com/gp/aw/d/B000E323IA?tag=wranglerorg-20

Video on how to do it:


View: https://youtu.be/33xJxkVVU08?si=m9Tu4v3uSaVX5npz

-Mac

 

[bbaudoin1981]

Covered some of it n my build thread:

Thread 'Operation Phoenix'

Jun 28, 2023

My wife and I left Fall Creek OR Friday morning headed to the three rivers area in Idaho where the Sellway, Lochsa and Clearwater converge to meet family and cast my 35 yr old sister's ashes into the river.

We decided to take a longer slower route and hit the OOHVA route 5-3...our missing link from our disasterous trip last summer when the rear end grenaded on my 97 Wrangler and we switched to our 2012 JK. It's all on YouTube.

We started in Seneca and camped out a few map pages in on a beautiful creek and meadow enjoying our new Tuff Stuff Trailhead rooftop tent (thankfully mounted to my...

• macleanflood
• Replies: 899
• Forum: TJ Build Threads & Member's Rides

• 
• 
• 

You basically need three Dorman parts and a caulk gun to press them together.

3/8 to 5/16 for the tank side:

https://www.amazon.com/gp/aw/d/B000E35WJW?tag=wranglerorg-20

5/16 to 5/16 for the line side:

https://www.amazon.com/Dorman-800-080-5-Fuel-Line-Connector/dp/B00A19LHXE?tag=wranglerorg-20

5/16 nylon fuel line:

https://www.amazon.com/gp/aw/d/B000E323IA?tag=wranglerorg-20

Video on how to do it:


View: %5BURL%5Dhttps://youtu.be/33xJxkVVU08?si=m9Tu4v3uSaVX5npz[/URL]

-Mac

Same concept I am trying to accomplish with the fittings I have. The fittings just do not fit the hard fuel line. Not sure why.

 

[macleanflood]

You tried more than just the fitting you've got?

-Mac

 

[bbaudoin1981]

You tried more than just the fitting you've got?

-Mac

I ordered the below fittings this morning. These were the fittings recommended by SS Tubes (Fine Lines)
Should have them in a few days to see if the fit is any better.
These fittings have rubber o rings on the inside of the female and have a threaded retaining nut.

https://www.summitracing.com/parts/RUS-644110
https://www.summitracing.com/parts/RUS-644120

 

[macleanflood]

Ah I think I see the issue.

With the part you have you should remove the plastic clip.

You should have a locking nut like this one from Racetronix.

-Mac

 

[bbaudoin1981]

Ah I think I see the issue.

With the part you have you should remove the plastic clip.

You should have a locking nut like this one from Racetronix.

View attachment 675038

-Mac

The part I have now is a push on connector with the plastic retaining clip. The part I ordered this morning has the locking nut like the one you have pictured. I am hoping this solves the problem. The part I do not understand is why the female side of the fitting I currently have bottoms out on the fuel line and doesn't allow me to insert it anymore onto the fuel line. It is almost like either the fuel line is not manufactured correctly or the fitting is not manufactured correctly. I have two fittings that came with the hose and two additional fittings and all of them do the same thing. I also have a -6AN male by 3/8 female fitting for the fuel tank side that attaches to the fuel pump on the tank. I tried the 3/8 fitting thinking maybe they sent 3/8 line instead of 5/16, but the 3/8 fitting is way too big. So either the 5/16 fuel line they sent is not manufactured correctly or the 5/16 fittings I received from Summit made by Russell are not manufactured correctly.

 

[bbaudoin1981]

Ordered new fittings last week. Same result. The fittings do not fit on the flared end of the hard fuel line. It appears that maybe the flared end of the fuel line is not flared correctly. Anyone with any insight as to why i cannot get any of these fittings to work correctly your input would be greatly appreciated.

 

[macleanflood]

Maybe it's 3/8 fuel line?

You've got the nut on the correct position in the first and third picture. Not the second...but I think you know that.

-Mac

 

[bbaudoin1981]

Maybe it's 3/8 fuel line?

You've got the nut on the correct position in the first and third picture. Not the second...but I think you know that.

-Mac

I checked it with 3/8 fuel line fittings and they are way too loose. It is 5/16 line, but I think the flaring is incorrect. When I put the threaded fitting on the unflared side there is a little bit of play. When I place it on the flared side (picture that is in the incorrect position only for reference) there is almost no play. This is why I measured with calipers and there is a difference in size between the non flared and flared side of the fuel line. I think that is where I am running into trouble. I contacted SS tubes fine lines again and I am awaiting their response. Only think I can see is that the flare when manufactured is incorrect.

 

[macleanflood]

I'll try and grab a spare fuel hard line if I have one and measure it up this afternoon.

-Mac

 

[bbaudoin1981]

I'll try and grab a spare fuel hard line if I have one and measure it up this afternoon.

-Mac

That would be great. Appreciate all of the help Mac..!!

 

[ItchyDong]

It looks to me like this is just way too long.

Edit: I do see what you mean about it being too big at the flared end after paying attention to your measurements. .317 is big if it’s a 5/16 adapter. Idk.

 

[mrblaine]

I checked it with 3/8 fuel line fittings and they are way too loose. It is 5/16 line, but I think the flaring is incorrect. When I put the threaded fitting on the unflared side there is a little bit of play. When I place it on the flared side (picture that is in the incorrect position only for reference) there is almost no play. This is why I measured with calipers and there is a difference in size between the non flared and flared side of the fuel line. I think that is where I am running into trouble. I contacted SS tubes fine lines again and I am awaiting their response. Only think I can see is that the flare when manufactured is incorrect.

5/16" is .312-.313. They have definitely changed the diameter where it goes into the o-ring side of the fitting and not much you can do except get them to fix it. If you need, I can measure the OEM SS line in the same place for them to use as a reference if they are confused.

On a side note, the fact that Jeep used the short flex hose from the pump to the hard line as an adapter has always confused me. Pump quick disconnect is 3/8" and the hard line is 5/16". Very odd but it works.

 

[bbaudoin1981]

View attachment 676259
It looks to me like this is just way too long.

Itchy, I put the threaded side on this portion just to see if it would fit over the fuel line. This part of the fitting goes on the left side of the flare. The other part of the fuel fitting slides over this side. There are two rubber O Rings that seal the fuel line on this side and then this threaded portion threads into it to secure it. If you look at my above pictures, this side of the flare is bigger than the fuel line. It seems to me that the flaring is incorrect. I could be wrong, but that is what I am leaning towards. See picture below of how the fitting is supposed to go together. The fitting bottoms out and I cannot slide it down onto the fuel line to be able to thread the retainer side onto it. Hope that makes any kind of sense to understand....lol

 

[mrblaine]

View attachment 676259
It looks to me like this is just way too long.

It isn't. That is about the standard length beyond the stop collar.

 

[bbaudoin1981]

5/16" is .312-.313. They have definitely changed the diameter where it goes into the o-ring side of the fitting and not much you can do except get them to fix it. If you need, I can measure the OEM SS line in the same place for them to use as a reference if they are confused.

On a side note, the fact that Jeep used the short flex hose from the pump to the hard line as an adapter has always confused me. Pump quick disconnect is 3/8" and the hard line is 5/16". Very odd but it works.

mrblaine, appreciate the reply. I saw a few threads that you commented and was hoping you would see this one to give me some advice. I really think they just made a bad flare on this set of lines. I agree I do not understand why it goes from 3/8 to 5/16 and unfortunately I cannot find any OEM replacement items, so I am trying to just get everything replaced with something. I think I am headed in the right direction, I just need to get the correct sizing on the line for the fittings to work properly. I am waiting on SS tubes to reply to me so I will definitely report back with everything once I get an answer.
There is not much information that I can find on replacing the entire fuel line from tank to fuel rail which is what I am trying to accomplish.

 

[macleanflood]

Pump quick disconnect is 3/8" and the hard line is 5/16". Very odd but it works.

I've always taken that as a sign that someone was pushing for an engine that needed more fuel.

-Mac