It would help if you stop calling it a flare. It isn't. That is typically referred to as a GM fuel line quick disconnect. Sadly, the forming tool that makes it is sold as a flaring tool so I understand the confusion.
2000 TJ Fuel Line Fittings
- Thread starter bbaudoin1981
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- fittings fuel fuel lines tj
They did a bad forming job on that line end for sure. If it helps, we've been converting to AN with the same adapters at the pump and hardline for years.
I think you might have that backwards. If I wanted more fuel, I'd bump the hard line up to 3/8".
Right...I'm saying someone had the right idea on the fuel pump and everything upstream didn't have the same aspirations.
-Mac
Vtx531
TJ Addict
Good luck. Trash customer service in my experience. I ended up having to call them and the customer service attitude was almost hostile.
That type of fuel fitting is covered by SAE standard number J2044_202505 (the part after the underscore is the revision date - May, 2025). The current standard costs $138, and I don't have access to it. However, I do have access to the standard document published two revisions back. It's J2044_200209 (September, 2002). I don't believe they would have changed the dimensions, and this is what the standard calls for with regards to the "nose":
Yours is definitely outside the acceptable diameter tolerances, but you'll have to measure length to see if the length is bad, too (not that it matters, if the diameter is already out of tolerance).
The manufacturer may not even be aware that there is a standard in place for these connectors. The SAE charges for their standards, which are copyrighted, and you have to agree not to share them if you purchase them. The automotive manufacturers all subscribe for easy access to all standards, but individual standards are pricey, so most aftermarket manufacturers aren't even aware that a standard exists. You could use the argument that they sold you a non-compliant part (to the SAE J2044_202505 standard), if they give you any grief, but if they aren't aware of that standard, they may not care.
Yours is definitely outside the acceptable diameter tolerances, but you'll have to measure length to see if the length is bad, too (not that it matters, if the diameter is already out of tolerance).
The manufacturer may not even be aware that there is a standard in place for these connectors. The SAE charges for their standards, which are copyrighted, and you have to agree not to share them if you purchase them. The automotive manufacturers all subscribe for easy access to all standards, but individual standards are pricey, so most aftermarket manufacturers aren't even aware that a standard exists. You could use the argument that they sold you a non-compliant part (to the SAE J2044_202505 standard), if they give you any grief, but if they aren't aware of that standard, they may not care.
I wonder what tool you use to form it. Because I'm guessing they bought a machine that forms the end much like a brake flare tool...rather than the spec...and maybe their dies have been used so much they're no longer in spec.
-Mac
-Mac
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I have the Mastercool 72485 set that does both 5/16" and 3/8" J2044 forming.
We have the same tool, we believe it will do the same things until we actually try it with a piece of stainless fuel line. It will do steel Bundy tube, it will not do that forming on SS or at least mine never has been able to.
Oh, yeah. That makes sense. Remember my struggles just to put an AN flare on stainless brake line? I wouldn't even try to use that Mastercool kit with stainless. It's too susceptible to cracking due to cold-working embrittlement. I forgot he was talking about stainless lines...
I bought that Mastercool kit to make a replacement non-stainless steel steering hardline for my '98 Subaru, which used a similar formed end with an o-ring on it at the rack. It was like a bubble flare, but with a stub nose like the J2044 (but shorter) and an o-ring on the stub. I don't recall what that type of formed end is called.
Same style fittings I am attempting to use so it definitely looks like I have a bad forming job on the lines that I received. Worries me about the comment about the customer service. Does anyone know of another source to get replacement ss fuel lines? This rabbit hole is starting to get deeper and deeper for me....
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The redneck in me wants to ask if there’s enough meat in the tube to sand .007” away 
The redneck in me wants to ask if there’s enough meat in the tube to sand .007” away
Literally it'll buff out...
-Mac
The previous owner cut the ss fuel line on the rear for some reason. They shoved a rubber hose onto the end and clamped it with two worm gear clamps for some reason.
I'm aware of that part, where is it cut, or put another way, how much flex stainless braided new line would you need to get to the fuel pump outlet?
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