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    #1

    Can't get fuel line to disconnect

    1991 Grand Marquis. Replacing the fuel system on this car because it sat for 11 years.

    I can't get the fuel line to disconnect from the 3/8" line at the fuel pump. I had to cut the steel line on the pump assembly in order to get the tank out. I have 4 hours into this connector, and it won't give. Soaked it Deep Creep, blew it out, tried both the plastic and metal line disconnect tools. The line is loose, the clips are loose, and I have a little in and out play, but it will not release.

    Any other ideas on getting it disconnected?
    Attached Files
    Tags: None
    #2
    When all else fails, heat? I can't remember, but that looks similar to the lines going into the fuel filter on my '88. I thought I was doing something wrong, turned out the lines were just STUCK.
    1985 LTD Crown Victoria - SOLD
    1988 Town Car Signature - Current Party Barge

    Comment

      #3
      I've been here. From my '91 thread:

      Originally posted by kishy View Post
      ...
      While disconnecting the quick-connects, the return side broke off. It was severely rusted at the quick connect, seized inside it, and twisted off by hand with almost no effort. Probably a good thing I caught that since I'm sure external leakage was imminent.

      Pulled the sending unit out. Was very pleased (and mildly surprised) to find the tank and sending unit are rust-free inside. I cleaned up the new sending unit (shelf dust), swapped over the fuel gauge sender component of it (since I know my old one works and I don't know that the new one does), and installed it. The supply side quick connect worked properly and sealed, while I cut the braided flex part of the return line off and used some 5/16" Gates EFI hose to make up the connection. I had tried to extract the rusted-off piece of line but it's stuck in there really solid; still, when I cut the hard line, I left enough room on both sides to maybe repair it in the future if I can salvage the flex hose. Testing showed there were no leaks, the pump is a thousand times quieter than the old one, and the engine runs and starts fine.













      ...​
      ​I fought with the little stub of line inside that quick-connect for quite a while before I gave up. In my case, because it's rusted off inside the connector, I have very few options for tools that can actually grab the stub, which is why I ended up cutting off the braided flexible line and just doing the rubber line.

      If I'm understanding your predicament right, that flexible line is fixed to the car, and therefore using heat would be pretty dangerous if there's fuel vapour accumulation under the car. My vote is also that heat will help (while using the release tool and also twisting the line with pliers...so we're up to you needing 3 hands at least) but don't burn down the car doing it.

      The pump hanger/sending unit combo was NOS but out of box. F0AU-9H307-BD​ purchased from spark-surplus on eBay. They have more of them but the price is substantially higher now. RockAuto has a handful of offerings for less.
      Last edited by kishy; 05-07-2026, 10:29 AM.

      Panthers: 83 GM 2dr | 84 TC | 85 CS | 88 TC | 91 GM | 94 CV
      Not Panthers: 85 Ranger | Ranger trailer | 89 Ranger | 91 Acclaim | 92 Jaaag | 05 Focus
      Gone: 97 CV | 83 TC | 04 Focus | 86 GM | Junkyards

      Comment

        #4
        when the metal scissor tool doesn't work, I grab the AC line tools and use those. The plastic is a little longer. I've also torn the cardboard off the box with the new filter and wrapped that around the line and shoved it inside as hard as possible and gotten it to release. There really needs to be a better tool for this job, but I've not found one yet.

        Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -- Albert Einstein
        rides: 93 Crown Vic LX (The Red Velvet Cake), 2000 Crown Vic base model (Sandy), 2003 Expedition (the vacation beast)

        Originally posted by gadget73
        ... and it should all work like magic and unicorns and stuff.

        Originally posted by dmccaig
        Overhead, some poor bastards are flying in airplanes.

        Comment

          #5
          If the line will spin and move inside of the socket its not rusted in place. Sounds like the tool isn't fully pushing the plastic retainer out of the way so it will let go. Does that plastic part push out on the outside of the line? If so maybe shove the disconnect tool in there, and then stick a pick underneath to pull it outward a little further.

          otherwise maybe it just wants a disconnect tool with a slightly fatter OD?
          86 Lincoln Town Car (Galactica).
          5.0 HO, CompCams XE258,Scorpion 1.72 roller rockers, 3.55 K code rear, tow package, BHPerformance ported E7 heads, Tmoss Explorer intake, 65mm throttle body, Hedman 1 5/8" headers, 2.5" dual exhaust, ASP underdrive pulley

          91 Lincoln Mark VII LSC grandpa spec white and cranberry

          1984 Lincoln Continental TurboDiesel - rolls coal

          Originally posted by phayzer5
          I drive a Lincoln. I can't be bothered to shift like the peasants and rabble rousers

          Everything looks like voodoo if you don't understand how it works

          Comment

            #6
            Kishy, thank you for the pictures. New fuel pump assembly showed up with a broken fuel float unit. Waiting for a replacement.

            Comment

              #7
              6 hours spread over 3 days of fighting that little bugger, and it finally let go. I figure that I got enough room to release the clips after I pushed the pipe in and twisted it with a lot of force. That pipe had a lot of rust on it behind the rib. 1/2" plastic connector tool wedged in there is what got the clips to release.

              Afterwards, I took some nylon engine cleaning brushes, along with Deep Creep, and cleaned out the connectors. Got a fair amount of grime out of both. I'm hoping that they don't leak on the new pump assembly.
              Attached Files

              Comment

                #8
                As long as the o-rings are not damaged, it should be fine.

                Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -- Albert Einstein
                rides: 93 Crown Vic LX (The Red Velvet Cake), 2000 Crown Vic base model (Sandy), 2003 Expedition (the vacation beast)

                Originally posted by gadget73
                ... and it should all work like magic and unicorns and stuff.

                Originally posted by dmccaig
                Overhead, some poor bastards are flying in airplanes.

                Comment

                  #9
                  might want to replace the O rings just to be safe.
                  86 Lincoln Town Car (Galactica).
                  5.0 HO, CompCams XE258,Scorpion 1.72 roller rockers, 3.55 K code rear, tow package, BHPerformance ported E7 heads, Tmoss Explorer intake, 65mm throttle body, Hedman 1 5/8" headers, 2.5" dual exhaust, ASP underdrive pulley

                  91 Lincoln Mark VII LSC grandpa spec white and cranberry

                  1984 Lincoln Continental TurboDiesel - rolls coal

                  Originally posted by phayzer5
                  I drive a Lincoln. I can't be bothered to shift like the peasants and rabble rousers

                  Everything looks like voodoo if you don't understand how it works

                  Comment

                    #10
                    Are there specific o-rings to use? Do you guys have a source for them? I'm not seeing anything on RockAuto.

                    Edit: Are these from NAPA the right ones? https://www.napaonline.com/en/p/NOE7...iq0Tomi2KXiMeg
                    Last edited by monterey1962; 05-11-2026, 08:16 PM.

                    Comment

                      #11
                      These quick connects are a different design than appear anywhere else on our cars. I'm not sure the O-ring is really serviceable, especially considering you're working overhead in the cramped space between the axle and fuel tank.

                      You'd have to use a really fine pick to scoop out the old one, and then lay the new one in.

                      I agree with changing them if you can manage it but it will be an absolute bear of a task. I'm not sure what the ideal replacement is.

                      Panthers: 83 GM 2dr | 84 TC | 85 CS | 88 TC | 91 GM | 94 CV
                      Not Panthers: 85 Ranger | Ranger trailer | 89 Ranger | 91 Acclaim | 92 Jaaag | 05 Focus
                      Gone: 97 CV | 83 TC | 04 Focus | 86 GM | Junkyards

                      Comment

                        #12
                        I've done this replacement before... and yes, it's a royal PITA. Picks are a must. I used the ones from Harbor Freight, so they don't have to be special. Used a pocket flat screwdriver to push the new one in so I didn't end up poking it. I had the problem at the fuel filter on the Expedition though, so it wasn't as much of a reach. Still a major PITA. I didn't use a specific o-ring, I had a selection of green ones and just managed to find the right size. Viton (FKM) is the material you want, but nitrile (buna-N) will also work (which is what I had - the green AC type - Hydrogenated Nitrile Butadiene Rubber - HNBR). I do not remember the size I used.

                        TL;DR - Nitrile works, AC-line rings will work too (another form of nitrile). Viton is better (FKM). Don't know the size since I had to deal with the fuel filter o-ring on my Expedition and picked from an AC universal ring kit I have.

                        Measure the OD of the pump lines and that will let you know what the ID should be just smaller than on the o-ring.
                        Last edited by sly; 05-12-2026, 02:42 PM.

                        Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -- Albert Einstein
                        rides: 93 Crown Vic LX (The Red Velvet Cake), 2000 Crown Vic base model (Sandy), 2003 Expedition (the vacation beast)

                        Originally posted by gadget73
                        ... and it should all work like magic and unicorns and stuff.

                        Originally posted by dmccaig
                        Overhead, some poor bastards are flying in airplanes.

                        Comment

                          #13
                          Originally posted by sly View Post
                          I've done this replacement before... and yes, it's a royal PITA. Picks are a must...
                          Wait a minute.. So those are o-rings just past those metal tabs in the 2nd pic in post #3 in this thread?
                          1985 LTD Crown Victoria - SOLD
                          1988 Town Car Signature - Current Party Barge

                          Comment

                            #14
                            yeah they live down past the fingers in the disconnect and seal against the steel tube between the flanged part of the steel line and the end. I don't remember if there is also a little plastic spacer down in there or not.

                            86 Lincoln Town Car (Galactica).
                            5.0 HO, CompCams XE258,Scorpion 1.72 roller rockers, 3.55 K code rear, tow package, BHPerformance ported E7 heads, Tmoss Explorer intake, 65mm throttle body, Hedman 1 5/8" headers, 2.5" dual exhaust, ASP underdrive pulley

                            91 Lincoln Mark VII LSC grandpa spec white and cranberry

                            1984 Lincoln Continental TurboDiesel - rolls coal

                            Originally posted by phayzer5
                            I drive a Lincoln. I can't be bothered to shift like the peasants and rabble rousers

                            Everything looks like voodoo if you don't understand how it works

                            Comment

                              #15
                              Hmm. Yeah, that sounds like a PITA alright. Guessing my '88 must be different as I don't recall seeing lines like that when I swapped my fuel pump. The lines going into the fuel filter were a bit weird, but the o-rings I saw on those lines were part of the line, not the connector.
                              1985 LTD Crown Victoria - SOLD
                              1988 Town Car Signature - Current Party Barge

                              Comment

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