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Old 02-28-2012, 04:52 PM   #1
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Fuel leak

Ok I know then bbk ssi intake has fuel leaks , how can you fix, or can you put different fuel rails on to solve it? Any help I would love
Thanks
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Old 02-28-2012, 05:00 PM   #2
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You mean the crossover pipes on them? Could be as simple as using a different o-ring on them. If your talking about the rails themself, I've never seen that problem on then. I'm running the Bbk ssiR intake which uses the same rails and I haven't had a problem with them leaking.
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Old 02-28-2012, 05:03 PM   #3
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Yes cross over tube . So just replace o-ring? Can get at any auto parts store?
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Old 02-28-2012, 05:07 PM   #4
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You might be able to but idk for certain, just make sure you get the right size o-ring meaning the same size that came out, maybe grab one size bigger and give that a shot. Just make sure you don't pinch the o-rings when putting it back together. Replace them them put it together, then prime the system and check for leaks, you shouldn't have to put the upper on to check for leaks.
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Old 02-28-2012, 05:10 PM   #5
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Cool thanks ill try that
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Old 02-28-2012, 05:12 PM   #6
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By bigger size I mean thicker not a larger size
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Old 02-28-2012, 05:13 PM   #7
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Got it thanks
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Old 02-28-2012, 05:41 PM   #8
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Re: Fuel leak

Also use white lithium grease on the o-ring before you put the rail on.
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Old 03-01-2012, 07:18 PM   #9
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Ok tried o-ring didn't seem to work, heres what I have to ask ..can you weld the cross over tube holes, an run a fuel line around back of rails where the holes are plugged... Now I have a bbk ssi intake ..ready to bite a nail into ...or (lol) just get new rails but I have to use bbk rails don't know if improved or not ...PLEASE HELP!!!
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Old 03-01-2012, 08:08 PM   #10
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Is it leaking around the o rings? You did bolt the rails back down after putting the new rings on so they are seated right?
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Old 03-02-2012, 04:07 AM   #11
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Yes I did
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Old 03-02-2012, 04:42 AM   #12
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Re: Fuel leak

Can you get some pictures of the problem areas?
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Old 03-02-2012, 04:52 AM   #13
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I will,it will be later in day
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Old 03-02-2012, 05:43 PM   #14
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This is where it leaks

Click image for larger version

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Old 03-02-2012, 05:55 PM   #15
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It doesn't look like the o ring is in all the way
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Old 03-02-2012, 05:57 PM   #16
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Thats add far as it will go in , once tighten down rails it wants to pull apart
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Old 03-02-2012, 06:03 PM   #17
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Hmmm, so it basically pulls the rail away from the lower when you tighten it down.... Try using 2 o rings on each side then tighten it down and see if that helps
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Old 03-02-2012, 06:06 PM   #18
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I will try, This might be dumb quetion but hey ....can the cross tube be welded on to rails?
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Old 03-02-2012, 06:08 PM   #19
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Quote:
Originally Posted by Quball19
I will try, This might be dumb quetion but hey ....can the cross tube be welded on to rails?
Honestly I don't know, you MIGHT be able to tap the holes and put a screw in plug in them then use a flex type gas line that screws into each side on the back of each rail but sounds like more headache than anything
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Old 03-02-2012, 06:11 PM   #20
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Thanks for your help, not really sure what going to do .. Really pissing me off but determined to get this ssi intake an rails to work
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Old 03-02-2012, 06:13 PM   #21
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Yeah I can understand your frustration, give the 2 o rings on each side of the tube a shot, I'm almost certain that should help
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Old 03-02-2012, 06:15 PM   #22
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I will had to walk away from it for awhile lol .... Thanks alot ill let you know how it comes out
Thanks again
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Old 03-02-2012, 06:20 PM   #23
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Not a problem, that's what we are here for heh, good luck!
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Old 03-02-2012, 06:48 PM   #24
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Re: Fuel leak

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Originally Posted by Quball19 View Post
This is where it leaks

Attachment 42285
OK, after quite a bit of research into this and not really finding a good fix, I have sent an email to BBK requesting information on how this issue can be resolved.


In the mean time I have a couple of ideas if you want to try them.


1. Try installing the tube with 2 or more o-rings (not sure how many will actually fit) pressed onto each end of the tube. Lubricate them and be careful installing to ensure the o-rings do not get cut or slip over the end of the tube.


2. This mod idea may destroy the crossover tube so use it at your own discretion.
First, try to stack at least 2 o-rings onto each end of the tube, then "very carefully" flare the end of the tube out to where it will just fit into the rails. If you go a bit to big you can file down the circumference with a metal file. Be sure to blow away any metal filings. You should be able to attach a flaring tool right behind the bulge in the tube on each end and flare out the end. As an alternative if you do not have access to a flaring tool, the tube can also be flared on the ends with a small ball peen hammer, taking care to not get off centered or strike too hard and damage the tube. A second hammer and friend to help hold the tube or strike the ball peen would be a big help. Set the rounded end of the ball peen into the end of the tube and tap the face of it with another hammer to flare the tubing end.


My theory for the second idea is that with the tube end flared out it will restrict the movement of the crossover tube and the flared end will help direct the pressure through the tube better, leaving less of it to try and push past the o-rings.
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Old 03-02-2012, 06:54 PM   #25
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Quote:
Originally Posted by Trojan Horse

OK, after quite a bit of research into this and not really finding a good fix, I have sent an email to BBK requesting information on how this issue can be resolved.

In the mean time I have a couple of ideas if you want to try them.

1. Try installing the tube with 2 or more o-rings (not sure how many will actually fit) pressed onto each end of the tube. Lubricate them and be careful installing to ensure the o-rings do not get cut or slip over the end of the tube.

2. This mod idea may destroy the crossover tube so use it at your own discretion.
First, try to stack at least 2 o-rings onto each end of the tube, then "very carefully" flare the end of the tube out to where it will just fit into the rails. If you go a bit to big you can file down the circumference with a metal file. Be sure to blow away any metal filings. You should be able to attach a flaring tool right behind the bulge in the tube on each end and flare out the end. As an alternative if you do not have access to a flaring tool, the tube can also be flared on the ends with a small ball peen hammer, taking care to not get off centered or strike too hard and damage the tube. A second hammer and friend to help hold the tube or strike the ball peen would be a big help. Set the rounded end of the ball peen into the end of the tube and tap the face of it with another hammer to flare the tubing end.

My theory for the second idea is that with the tube end flared out it will restrict the movement of the crossover tube and the flared end will help direct the pressure through the tube better, leaving less of it to try and push past the o-rings.
+111111 I was going to suggest emailing Bbk but I've read on another mustang forum that they havent been getting any help with the issue from them, basically saying they have never heard of that issue but ya never know
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Old 03-02-2012, 06:54 PM   #26
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Are the rails used? Is there any chance the tube or rails could have been damaged?
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Old 03-02-2012, 06:58 PM   #27
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Kinda what I was thinking , yes came with car, thought about buying new ones and go from there, its ti bad can't use different ones
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Old 03-02-2012, 09:09 PM   #28
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Re: Fuel leak

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+111111 I was going to suggest emailing Bbk but I've read on another mustang forum that they havent been getting any help with the issue from them, basically saying they have never heard of that issue but ya never know
Well they can't claim that with my email.
I told them I did some searching and turned up dozens of issues with it, so anyone with half a brain would know to do the same type of search and see what turns up.


I also told them I was interested in buying, so that might get them moving, who knows/
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Old 03-02-2012, 09:13 PM   #29
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Re: Fuel leak

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Kinda what I was thinking , yes came with car, thought about buying new ones and go from there, its ti bad can't use different ones
You can do several different things.
1. Try the fixes I suggested.
2. See about getting a welding shop to TIG the holes shut and reroute a line around the back.
3. See if a machine shop can thread the holes and use some adapters and hard line to replace the crossover.
4. See if a welding shop can weld some fittings in there to do the same as #3 with hard line.
5. Take it off, go to BBK's business place and toss it through their front window.
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Old 03-02-2012, 10:12 PM   #30
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Quote:
Originally Posted by Trojan Horse

You can do several different things.
1. Try the fixes I suggested.
2. See about getting a welding shop to TIG the holes shut and reroute a line around the back.
3. See if a machine shop can thread the holes and use some adapters and hard line to replace the crossover.
4. See if a welding shop can weld some fittings in there to do the same as #3 with hard line.
5. Take it off, got to BBK's business place and toss it through their front window.
I'd do #5... Except I'd add the intake too!
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Old 03-03-2012, 06:19 AM   #31
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I like number 5 that sounds tge best lmao
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Old 03-03-2012, 05:36 PM   #32
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Ok found good tig welder, will let you know out come next week .....
Thanks guys.. crossing fingers hope this works it should
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Old 03-05-2012, 11:35 PM   #33
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Re: Fuel leak

Reply from BBK about fuel crossover leak issues.
Quote:
Originally Posted by Dave from BBK
The only major issue I'm aware of that we had in the past was the cross-over leaking. This was because of the o-rings not holding up properly. For customers with that setup, we sent out multiple o-rings that can be doubled up to provide a better seal. This was a while ago and since then we have upgraded the kit with new rails and a cross over that uses two aircraft grade aluminum 90 degree fittings and a piece of locking fuel line.

- Dave
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Old 03-06-2012, 05:10 AM   #34
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So, basically I am turning my old ones to new ones. Mine are welded up getting ready to repaint them and hook back up with my 90 degree lines. Thank you
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Old 03-06-2012, 07:11 AM   #35
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Re: Fuel leak

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So, basically I am turning my old ones to new ones. Mine are welded up getting ready to repaint them and hook back up with my 90 degree lines. Thank you
That's what it sounds like.
They should have replaced yours with a new set though, if they admitted there was a problem with them.


You're welcome and good luck.
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