I replaced the fuel filters on my F250 a few weeks ago like I've done several times since buying the truck. The fuel line for the filter under the hood had a 1/8" molded hose barb going into it for a return line from the injectors. Needless to say I managed to snap the barb off while trying to dissconct the housing. At 4:45pm my nearest dealer parts counter had closed early from covid-19 hysteria. I called another local dealer that informed me the part in question came part of a $160 fuel line assembly (good news was it was in stock).
I examined the part I had broken and decided to try and repair it. I snipped the broken remnants of the plastic barb off and remembered seeing a brass double ended hose barb at a hardware across town. The next morning I wasted time stopping at several parts stores and hardware to see if I could find it closer. No luck but I did find one where I had remembered seeing it the first time.
On my way home my wife had me stop here and there for different reasons. When I got home that 1/8" by 1" single brass barb in the tiny Ziploc bag was no where to be found.
Back to the hardware. Once home with 2 more barbs this time, I measured the outer diameter of the barb and found a tad smaller drill bit and carefully drilled through the thin plastic where the molded barb broke off. I coated the outside of brass barb in super glue to kinda lube and bond and gently pressed it in with channel locks. It snuggly fit so I let the glue dry overnight.
I Googled my fuel fitting predicament and located a replacement part for $30 On eBay. Of course I hit the buy it now button. The next day I reinforced my superglue job with a little fuel tank safe epoxy.
The following day, (Monday) went to put everything back together and broke a quick connect clip. My nearby local dealer had opened back up so I called. After emailing me some parts diagrams he told me " I think I have the clip you need but it's sold with a $10 fitting. I drove up there to check it out. It was the part I'd spent all weekend repairing and told it was sold in an assembley and bought on eBay for $30....just not the little retaining clip I needed (ford did improve the design to protect the barb from getting broken on the new part). I bought it anyway in case my repair plan didnt pan out and the ebay item wasnt right or useable.
After examining the function of the broken clip I decided I could fish a small zip tie in there, it would grab the fuel line as the clip intended and hold the fuel line in place. The worst that could happen would be a fire and I would make sure to leave my phone in the truck so someone else would have to call the fire dept to put it out.
I bled the air out as per Ford's procedure and she fired right up and ran great. No leaks, not sucking air, no fire. Time will tell how my Super glue/epoxy/zip tie repair will hold up, but I'll know I'm out $160 for that fuel line assembly which will come with another "T" fitting that I already have 2 extras. (BTW, the ebay part came in, it was new in package Ford part)
https://www.tascaparts.com/oem-part...N0-4uXN5YqwAwJLuJNPQ1Bj5cGIaAiWWEALw_wcB