Fuel Line on Frame Rail

Dammit, i fix one thing and 3 more things pop up. i was swapping in a D44 rear and while fooling with the e-brake cables i see this:



i appears to have been there a while, and is not leaking. the xj does feel sluggish

can i simply cut out a 5" section and replace it with rubber fuel line and 2 fuel line hose clamps per side?

You must get better gas mileage that way.


If you cut the line you'll need to flare it, otherwise a rubber hose will just pop off sometime on the freeway.

Since there's no rust on the line, you might be able to get a couple of compression fittings (the ones with the little rings that slip onto the line). They're illegal on brake lines, but fine on something like this.

good idea
might try something like this for $20
http://store.summitracing.com/partd...Ntk=KeywordSearch&Ntt=fuel+filter+compression

i know i have the in-tank filter (98XJ) but i dont think a little extra filtration would hurt

LouisianaZJ said:

good idea
might try something like this for $20
http://store.summitracing.com/partd...Ntk=KeywordSearch&Ntt=fuel+filter+compression

i know i have the in-tank filter (98XJ) but i dont think a little extra filtration would hurt

Click to expand...

Make sure it's rated for the ~40psi fuel pressure...

well, if i wanted to do just a compression fitting for now, what exactly type of fittings/ line? would i need?
it is about 3/4" of damage before the line is normal

is brass OK?

I´d just put a quality piece of rubber fuel line in there, run it a couple of inches onto the existing hard line (a little lub of some kind will help) and double hose clamp both ends. If cut with a tubing cutter, smooth the outside edges with a very small file a bit so the rubber slides on there without catching the edge. Use a sharp knife or a deburring tool, to clean the ridge out of the inside (good idea, but not absolutly necessary)(use a vacuum cleaner to keep the filings/metal flakes, out of the line).
If you cut it with a saw, a vacuum cleaner will also help keep the filings out of the line.
Fittings most ways, will leak from vibration or what not faster than the clamps, and arn´t really necessary until the pressures get up around 100 PSI.
I cut in a Toyota fuel filter (for fuel injection) (about twice the size of an early Jeep and a bit finer) in my 96, never had any trouble with it leaking.

i fixed it today. i ended up cutting out about a 2" section w/ a tubing cutter. and i put on a 12" 5/16" goodyear rubber fuel line (said 50psi on it) with 4 clamps.
i used atf to lube the metal line. i dont think i got too many filings in there... hope not, i just swabbed out the line with a q tip where i cut it.
i noticed it is alittle peppier with the full flow restored