Series 60 fuel system woes

Ok, I'm seriously frustrated here.

I've got a 2004 S60 14l with (I assume) stock primary and secondary spin on fuel filters, with a small shutoff ball valve after the secondary filter housing. This ball valve is shot. The stem rocks from side to side and the packing is gone, to the point I suspect the truck may be sucking air under heavy load. I was poking around this morning and bumped the valve handle while the motor was running, and got sprayed with diesel.

Ok, time for a new valve. WTF are the out ports in this filter head threaded with?! They're not SAE NPT, compression or flare threads. Are they metric? AN-something? The fuel line ends seem to be 3/8" NPT. I can't find an OEM shutoff valve to save my life so I was planning on replacing with a standard full port quarter turn ball valve. Only problem is those threads. Smaller bore than 3/8" NPT but similar thread pitch and spacing. Oh, and the valve itself is odd, has some sort of steel bushing with a washer and O ring, on the side that faces the filter housing. This bushing is stuck and cross threaded. I don't know what the deal is but I'm about to have a local machine shop drill and tap the housing to NPT if I can't find another solution.

Ideas? I can't be the only one who's run into this. Will post pics of offending parts tomorrow, it's dark out under the shade tree now

 

Think I'm going to put a Davco setup on eventually, just broke under load on this one (thankfully hadn't picked it up yet).

What size AN lines did your setup use? I'm curious...also do you have any pictures?

 

Well, thanks to someone else's ham handed pipe assembly skills, I now need a new filter base as well. Apparently the Boss threaded end (thanks JohnP3!) was cross threaded into the filter housing and wiped out the first 4 threads. That explains why it was so difficult to get off...

I ought to ditch all the stock stuff forward of the tanks, install a Davco, and run AN lines for everything else. At least the fitting sizes and threads might be consistent then.

 

I see Davco 382 setups going for mid $200 range on eBay. Think I'd like a heated base though since I run northeast. Almost every truck I've ever driven has had one, except for my stint at FFE. TMC had them and provided us with a few spare filters, a wrench and a drain pan.