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Fuel Bail Repair

This stainless fuel quick-connect was used on Ford trucks from '92 to at least '97, and it can be troublesome. It requires not only special tools that weren't necessary for the older plastic fittings; it also requires a filter with longer nipples.

. . . .

Connecting to an older filter prevents any tool from releasing the bail, so the only relatively-safe way to disconnect it is to pull the line until the bail's fingers collapse, hopefully allowing the nipple to come out. If not, the nipple must then be cut or broken off the filter (risking sparks & fire) before digging the bail out to release the nipple from the fitting.

'87-96 fuel filter Motorcraft FG872 long nipples work with both styles of quick-connect
'87-91 (short nipple) Motorcraft FG800A plastic hairpin quick-connects ONLY



But even with the correct filter, the fitting can still jam due to dirt building up inside the fitting, preventing the fingers from fully retracting & clearing the nipple. That's what happened to this one - the mud inside is visible in the top photo, as is the bent finger on the bail (red pointer).
IF THE IMAGE IS TOO SMALL, click it.
In either case, repairing or replacing the bail is relatively easy once the nipple is out of the fitting.

1. Use a pick or needle-nose pliers to remove the bail from the fitting. It must be pushed INTO the fitting until its outer lip clears the fitting's lip. Then bend the bail slightly inward all the way around, working it up & out.
2. Pull the bail out and inspect the fingers. Use pliers & a round die (like a socket in a vise) to straighten each finger, and curve the ring smoothly. If it can't be re-shaped, buy a replacement fitting and transfer its bail into the original fitting. Note the mud packed inside which prevented the fingers from fully retracting.
3. With the fitting inverted, brush & rinse all the dirt out, allowing it to drain OUT of the fitting instead of into the fuel line. Use carb cleaner to rinse any residue or contamination out of the lines.
4. After ensuring that no dirt or debris remains inside the fitting, apply a few drops of clean motor oil to the 2 O-rings deeper inside the line, and reinsert the bail so that it snaps into place behind the fitting's lip.
5. Make sure that each long, thin finger lies flat against the wall of the fitting and rests against the flat face at the back (dark blue pointer). Each short, wide finger (light blue pointer) should angle slightly inward to engage the ring on the nipple.

In the future, use a garden hose or carb cleaner to rinse the mud out of the fitting before attempting to insert the tool. Never use penetrating oil or silicone grease near the fuel system O-rings.

Replacement 10.5mm spring bails are available from Ford as E9UZ-9B307-B. Dorman also offers them in 10.5mm & 13mm, and as a pack of 3ea of both sizes.

3/8" hairpin clip 2F1Z-9A317-BA Dorman 800-004 (5-pk)
5/16" hairpin clip 2F1Z-9A317-AA Dorman 800-003 (5-pk)