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Tahoe & SuburbanThe power, space, and brutal towing ability make the Tahoe and its longer sibling, the Suburban, arguably the best full size SUV's on the market today.
Resolved.
Took many days to drop the tank as no parts came out easily.
With tank down , I cut the two fuel tank nylon fuel lines (supply 3/8, return 5/16) near the front leading edge of the fuel tank.
Then I spliced in Dorman nylon tubes ( 3/8 and a 5/16 ) that also have new quick disconnects to join the supply fuel steel line and the return steel fuel line.
Each nylon Dorman repair package was $20. I did not use their metal connectors that require heat and possibly compression fittings . I just wanted the nylon tubes with the quick 3/8 " and 5/16 " disconnects already fused to the nylon tubes.
I used Dorman shark-bite like connectors to join the new nylon tubes to the old nylon tubes that come from the fuel pump which I cut off the ends.
IIRC, each Dorman nylon shark-bite like connector package of 2 was $10.
That procedure was quick and easy. Just slid the shark-bite onto each nylon piece. Nothing to heat, nor compression fittings. Hope it does not leak fuel. Never tried these in auto repair.
This 2003 Tahoe fuel line R/R saga has been going on for 15 days and still going.
Here is a follow-up of the nylon fuel line repair with photos for the benefit of others.
The only reason that I dropped the tank was to be able to access/repair the dysfunctional fuel tank nylon quick disconnect components. Along the way, both fuel tank strap bolt/speed nuts were broken ( 2 days repair) and the fuel pump quick disconnect took 3 days to unplug. I packed grease onto the new fuel tank speed nuts/bolts to prevent moisture from ever reaching /rusting the speed nuts/bolts.
Last edited by stilllearning6; Oct 28, 2020 at 6:22 AM.
Reason: additional info