cummins 5.9 fuel line leaks

Stewart Way · 04-18-2012, 08:09 PM

I have a 2005 2500 dodge diesel. For the second time it has developed a fatigue crack in a hard line from the fuel rail to the injector. This one was on #4. The line is about 7" long ($86) with a clamp in the middle. Not sure which one it was the first time because it quit in the middle of traffic and had to be towed and fixed under warranty.
I have looked on the internet and have found this is a common problem. They crack right behind the end of the ferrel at the injector end. Enough that some guys are keeping an extra one in the truck and the 2 wrenches to change it.
Anyone seen this problem and or know of a solution?

Run to Rund · 04-19-2012, 12:28 AM

Tighten the new one carefully so the support/vibration bracket has no stress on the line. #6 occasionally cracked until a support bracket was added around 2005 or so; it goes to the engine lift bracket bolt that is converted to a bolt/stud. #4 is the most common one to fail for some reason. Get it from Cummins for about $25-30.

Jim Wahl · 05-09-2012, 09:47 AM

Quote:

Originally Posted by Run to Rund

Tighten the new one carefully so the support/vibration bracket has no stress on the line. #6 occasionally cracked until a support bracket was added around 2005 or so; it goes to the engine lift bracket bolt that is converted to a bolt/stud. #4 is the most common one to fail for some reason. Get it from Cummins for about $25-30.

I have an '05 2500 w/ Cummins 5.9. I have all of 44,000 miles on it, mostly towing, should I be worried? I've never heard of this! Jim

.

Run to Rund · 05-09-2012, 01:09 PM

I worry a lot about a lot of things so I carry spare lines and a 3/4" open end wrench. I wouldn't say the failure is common but it happens enough to be cautious, especially if you go on long trips, etc. You can't just continue running with a cracked line as it is under rail pressure all the time. Rail pressure does go up with more accelerator pedal, from about 5000 psi at idle to a max of about 23,000 psi.

Jim Wahl · 05-09-2012, 11:28 PM

Here ya go:

http://www.dieselbombers.com/5-9-lit...ctor-line.html

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FED 387 · 05-10-2012, 08:57 AM

what years are affected??? are any immune or is it a problem that any 5.9 cummins might have??? my son has a 2008

Bob Mulry · 05-10-2012, 11:23 AM

Hi All,

Tese are a great resource for information on all Dodge Diesels.....

http://www.dieseltruckresource.com/dev/index.php

http://www.cumminsforum.com/forum/

Bob

Run to Rund · 05-10-2012, 01:37 PM

The original club and its website are still very good:
www.turbodieselregister.com

Bob Mulry · 05-10-2012, 09:45 PM

Quote:

Originally Posted by Run to Rund

The original club and its website are still very good:
www.turbodieselregister.com

I used the TDR forum for years and when they started to charge $35.00 a year to subscribe, I found my information at the free sites.

Bob

cad · 05-11-2012, 08:08 AM

Quote:

Originally Posted by FED 387

what years are affected??? are any immune or is it a problem that any 5.9 cummins might have??? my son has a 2008

I haven't heard of any issues with the 6.7, and thankfully I've only had 1 injector fail on my 06 5.9, which filled the engine with diesel

.

Clark

04-18-2012, 08:09 PM	#1
Stewart Way Member Join Date: Aug 2003 Location: Atlanta Posts: 475 Likes: 15 Liked 70 Times in 21 Posts	cummins 5.9 fuel line leaks I have a 2005 2500 dodge diesel. For the second time it has developed a fatigue crack in a hard line from the fuel rail to the injector. This one was on #4. The line is about 7" long ($86) with a clamp in the middle. Not sure which one it was the first time because it quit in the middle of traffic and had to be towed and fixed under warranty. I have looked on the internet and have found this is a common problem. They crack right behind the end of the ferrel at the injector end. Enough that some guys are keeping an extra one in the truck and the 2 wrenches to change it. Anyone seen this problem and or know of a solution? __________________ Stewart Way 2424 SS

04-19-2012, 12:28 AM	#2
Run to Rund Senior Member Join Date: Sep 2007 Posts: 574 Likes: 6 Liked 44 Times in 22 Posts	Re: cummins 5.9 fuel line leaks Tighten the new one carefully so the support/vibration bracket has no stress on the line. #6 occasionally cracked until a support bracket was added around 2005 or so; it goes to the engine lift bracket bolt that is converted to a bolt/stud. #4 is the most common one to fail for some reason. Get it from Cummins for about $25-30.

05-09-2012, 11:28 PM	#5
Jim Wahl Veteran Member Join Date: Jan 2002 Location: Central Florida Posts: 5,841 Likes: 626 Liked 672 Times in 121 Posts	Re: cummins 5.9 fuel line leaks Here ya go: http://www.dieselbombers.com/5-9-lit...ctor-line.html . __________________ Jim Wahl....NHRA #2239 S/SS - IHRA # 8 Stock, D2 Stock Champion (forever I guess) 2019 Baby Gators Stock Champion 2009 D2 National Open Stock Champion 1981 D2 West Palm Beach LDRS SS Runner Up Past President, Southern Stock / Super Stock Association. SSSSA Forum Moderator

05-10-2012, 11:23 AM	#7
Bob Mulry VIP Member Join Date: Apr 2002 Location: Coarsegold, CA Posts: 1,017 Likes: 57 Liked 321 Times in 101 Posts	Re: cummins 5.9 fuel line leaks Hi All, Tese are a great resource for information on all Dodge Diesels..... http://www.dieseltruckresource.com/dev/index.php http://www.cumminsforum.com/forum/ Bob __________________ Bob Mulry 7516 STK A & M Motorsports

05-10-2012, 01:37 PM	#8
Run to Rund Senior Member Join Date: Sep 2007 Posts: 574 Likes: 6 Liked 44 Times in 22 Posts	Re: cummins 5.9 fuel line leaks The original club and its website are still very good: www.turbodieselregister.com

05-09-2012, 01:09 PM	#4
Run to Rund Senior Member Join Date: Sep 2007 Posts: 574 Likes: 6 Liked 44 Times in 22 Posts	Re: cummins 5.9 fuel line leaks I worry a lot about a lot of things so I carry spare lines and a 3/4" open end wrench. I wouldn't say the failure is common but it happens enough to be cautious, especially if you go on long trips, etc. You can't just continue running with a cracked line as it is under rail pressure all the time. Rail pressure does go up with more accelerator pedal, from about 5000 psi at idle to a max of about 23,000 psi.

05-10-2012, 08:57 AM	#6
FED 387 VIP Member Join Date: Jun 2006 Posts: 3,349 Likes: 324 Liked 280 Times in 150 Posts	Re: cummins 5.9 fuel line leaks what years are affected??? are any immune or is it a problem that any 5.9 cummins might have??? my son has a 2008