Chrysler Full-Size Trucks 1989-1996 Repair Guide

Quick-Connect Fittings

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Quick-connect fittings are used at several fuel system connections. Most fittings have one or two retainer tabs that must be released before disconnecting the fittings from the fuel tube. Another type of quick-connect fitting uses a full-round plastic retainer and is usually black in color.

The fuel fittings with one tab are known as the "single-tab type.'' The fittings with dual tabs are the "two-tab type.'' Most earlier models (before 1994) used the single-tab type. The single tab-type is equipped with a single pull tab. The two-tab type has tabs located on both sides of the fitting. The fitting that uses a full-round retainer ring is known as the plastic retainer ring type fitting.

REMOVAL & INSTALLATION



Single-Tab Type

See Figures 1 and 2

  1. Relieve the fuel system pressure, as described later in this section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Clean the fitting of any foreign material before disassembly.
  6.  



Click image to see an enlarged view

Fig. Fig. 1: A common single-tab type quick-connect fitting

  1. Press the release tab on the side of the fitting to release the pull tab.
  2.  


WARNING
The release tab must be pressed prior to releasing the pull tab or the pull tab will be damaged.

Click image to see an enlarged view

Fig. Fig. 2: Remove the pull tab from the single-tab type quick-connect fitting


  1. While pressing the release tab on the side of the fitting, use a small prytool to pry up the pull tab.
  2.  
  3. Raise the pull tab until it separates from the quick-disconnect fitting. Discard the old pull tab.
  4.  
  5. Disconnect the quick-disconnect fitting from the fuel system component being serviced.
  6.  
  7. Inspect the fitting body and fuel system component for damage. Replace as necessary.
  8.  

To install:
  1. Before connecting the fitting, check the condition of the fitting and component being serviced. Clean with a lint-free cloth, then lubricate them with clean engine oil.
  2.  
  3. Insert the quick-connect fitting into the fuel tube or fuel system component until the built-on stop on the fuel tube or component rests against the back of the fitting.
  4.  
  5. Obtain a new pull tab. Push the new tab down until it locks in place in the quick-connect fitting.
  6.  
  7. Pull firmly (about 15-30 lbs. or 6.75-13.5 kg. of force) on the fuel tube to verify the fitting is locked.
  8.  
  9. Connect the negative battery cable.
  10.  
  11. Start the engine and check for leaks. Shut off the engine immediately if any are detected and repair the leaks.
  12.  

Two-Tab Type

See Figure 3

  1. Perform the fuel system pressure release.
  2.  
  3. Disconnect the negative battery cable.
  4.  



Click image to see an enlarged view

Fig. Fig. 3: A common two-tab type quick-connect fitting

  1. Clean the fitting of any foreign material before disassembly.
  2.  
  3. Squeeze the plastic retainer tabs against the sides of the fitting with your fingers. Pull the fitting from the fuel system component. The plastic retainer will stay on the component. The O-rings and spacer will remain in the fitting connector body.
  4.  


WARNING
When the fitting is disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small prytools. After removal, inspect the retainer for cracks or any damage.

  1. Inspect the fitting body and fuel system component for damage. Replace as necessary.
  2.  

To install:
  1. Before connecting the fitting, check the condition of the fitting and component being serviced. Clean with a lint-free cloth, then lubricate them with clean engine oil.
  2.  
  3. Insert the quick-connect fitting to the fuel system component being serviced and into the plastic retainer. When a connection is made, a click will be heard.
  4.  
  5. Pull firmly (about 15-30 lbs. or 6.75-13.5 kg. of force) on the fuel tube to verify the fitting is locked.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for leaks. Shut off the engine immediately if any are detected and repair the leak.
  10.  

Plastic Retainer Ring Type

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Perform the fuel system pressure release.
  4.  
  5. Clean the fitting of any foreign material before disassembly.
  6.  



Click image to see an enlarged view

Fig. Fig. 4: The plastic retainer ring type quick-connect fitting

  1. To release the fitting, firmly push the fitting towards the component it's attached to while firmly pushing the plastic retainer ring into the fitting. Pull the fitting from the component. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector body.
  2.  

The plastic retainer ring must be pressed squarely into the fitting body. If this retainer is cocked during removal, it may be difficult to remove the fitting. Use an open end wrench on the shoulder of the plastic retainer ring to air the disconnection.

  1. Inspect the fitting body and fuel system component for damage. Replace as necessary.
  2.  

To install:
  1. Before connecting the fitting, check the condition of the fitting and component being serviced. Clean with a lint-free cloth, then lubricate them with clean engine oil.
  2.  
  3. Insert the quick-connect fitting to the fuel system component being serviced. When a connection is made, a click will be heard.
  4.  
  5. Pull firmly (about 15-30 lbs. or 6.75-13.5 kg. of force) on the fuel tube to verify the fitting is locked.
  6.  
  7. Connect the negative battery cable.
  8.  
  9. Start the engine and check for leaks. Shut off the engine immediately if any are detected and repair the leak.
  10.  

 
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