Down the Rabbit hole
wowsers, what a fuster Cluck! i bought a 94 s10 blazer.. for $400.
it had leaky fuel lines near the tank... one look at those lines and I knew the second I touched them, they were going to snap off.
I got ahold of a place called www.linestogo.com and for $180 they sent me both the pressure and return lines in pre-bent steel, along with the stainless braided flex lines (and fuel filter)
after a miserable time of getting the tank out, the supply line snapped right off when i lowered the tank.. but since I played it smart, and ordered a new fuel sender unit too, I just cut the lines off with an air saw and didn't' have to deal with trying to get the fittings apart.
then while I was cleaning the tank up getting it ready for a quick coat of paint, I discovered it had pin holes in it just above the 1/2 tank point.. that would have REALLLLLLY P'd me off if I had got it all back together and not discovered that until the first time I put $50 worth of fuel in it!
so I ordered a brand new tank from Spectra from RockAuto.com ($62)
I ordered a brand new fuel sender assembly too.. ($30)
then I figured I'm in it this far, went ahead and put a new Bosch fuel pump in too, ($80) the truck only has 98k miles.. but I figured why not?
I got lucky with the front fittings.. even tho they're in a nightmare of spot over the top of the transfer case drop, sandwiched in next to the torsion spring cross member... I soaked them in PB blaster, several times a day for a week, waiting for the heat/humidity to break.. and they came apart with surprising ease!
Then, I discovered, someone had removed this tank b4.. the upper, driver's side strap was not re-installed.. no real surprise.. it made putting the tank back in a real joy, as the steel lines have to come over the top of the strap, not leaving a lot of room to get in there to connect the lines.
So.. i ordered new straps from Amazon (They were cheaper when i factored in RockAuto's kind of expensive shipping costs)
then to top it all off, I discovered the ground strap for the filler neck was missing too.. so I had to get creative to re-create that, as I didn't want to buy another
almost got this blasted tank back in.. then I discovered where I cut the filler neck vent hose ... it was too short.. thankfully my local o'rileys had 5/8" fuel line on a roll.. with some help from the heat gun, I managed to re-create that tight 90° bend without it kinking..
finally got it all back together! spent way more than I wanted too.. but at least I know the fuel system is solid!
I'll post some pics when I take the time to get them off my phone and onto the PC!
it had leaky fuel lines near the tank... one look at those lines and I knew the second I touched them, they were going to snap off.
I got ahold of a place called www.linestogo.com and for $180 they sent me both the pressure and return lines in pre-bent steel, along with the stainless braided flex lines (and fuel filter)
after a miserable time of getting the tank out, the supply line snapped right off when i lowered the tank.. but since I played it smart, and ordered a new fuel sender unit too, I just cut the lines off with an air saw and didn't' have to deal with trying to get the fittings apart.
then while I was cleaning the tank up getting it ready for a quick coat of paint, I discovered it had pin holes in it just above the 1/2 tank point.. that would have REALLLLLLY P'd me off if I had got it all back together and not discovered that until the first time I put $50 worth of fuel in it!
so I ordered a brand new tank from Spectra from RockAuto.com ($62)
I ordered a brand new fuel sender assembly too.. ($30)
then I figured I'm in it this far, went ahead and put a new Bosch fuel pump in too, ($80) the truck only has 98k miles.. but I figured why not?
I got lucky with the front fittings.. even tho they're in a nightmare of spot over the top of the transfer case drop, sandwiched in next to the torsion spring cross member... I soaked them in PB blaster, several times a day for a week, waiting for the heat/humidity to break.. and they came apart with surprising ease!
Then, I discovered, someone had removed this tank b4.. the upper, driver's side strap was not re-installed.. no real surprise.. it made putting the tank back in a real joy, as the steel lines have to come over the top of the strap, not leaving a lot of room to get in there to connect the lines.
So.. i ordered new straps from Amazon (They were cheaper when i factored in RockAuto's kind of expensive shipping costs)
then to top it all off, I discovered the ground strap for the filler neck was missing too.. so I had to get creative to re-create that, as I didn't want to buy another
almost got this blasted tank back in.. then I discovered where I cut the filler neck vent hose ... it was too short.. thankfully my local o'rileys had 5/8" fuel line on a roll.. with some help from the heat gun, I managed to re-create that tight 90° bend without it kinking..
finally got it all back together! spent way more than I wanted too.. but at least I know the fuel system is solid!
I'll post some pics when I take the time to get them off my phone and onto the PC!
Wow. Congrats!
Then again your truck is 26 y.o. and depending on where it lived most of its life, the environment could have been pretty tough on it.
I had 92 up until about 10 years ago and I had to have a new fuel pump put into it. It cost me $500 about 15 years ago.
If I had a fuel pump issue now on my 99, I'd do it myself but I'm going to do my best to avoid that by never letting my tank go below 1/4 full if I can help it.
Then again your truck is 26 y.o. and depending on where it lived most of its life, the environment could have been pretty tough on it.
I had 92 up until about 10 years ago and I had to have a new fuel pump put into it. It cost me $500 about 15 years ago.
If I had a fuel pump issue now on my 99, I'd do it myself but I'm going to do my best to avoid that by never letting my tank go below 1/4 full if I can help it.
needs new windshield
high/lo beam switch gets stuck in the high beam position.
hot/cold selector doesn't work, (currently stuck in full hot)
4x4 switch is 100% inoperative. (4x4 works, just not the switch)
driver's side window likes to roll forward instead of going up
it rides like a hay wagon.. ( I need to make sure someone didn't crank the torsion bars up for a cheap lift)
it may need a front seal on the transmission
temp gauge in the dash doesn't work (it's the gauge, computer shows correct temp on the tech1)
needs a driver's side ebrake cable (it was cut)
probably never had a full 4x4 service either.
it has a random misfire that needs looking into.
at least the 4l60e seems happy enough.
i addressed the fuel lines first since I like to put safety issues first.
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Nick_K5_Blazer
Full Size K5 (1969-1991) GMT415 (1992-1994) Tech
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Jan 18, 2011 06:35 PM




