Replacing The Fuel Pump In A Ford F-150: Step-By-Step Guide

The fuel pump in a Ford F-150 is not especially challenging to replace. However, accessing it can be difficult because it is situated inside the fuel tank. There are two ways to reach the fuel pump: either by removing the fuel tank or by removing the truck bed. This article will outline the steps for both methods and provide useful tips for a successful fuel pump replacement.

Siphoning fuel from the tank

To siphon fuel from the tank of a Ford F-150, you will need a clear hose and an air pump.

Firstly, cut a length of clear tubing to at least 6 feet long. The tubing should be three-fourths to 1 inch in diameter for the best flow rate. If the tube is too large, it can be difficult to achieve the necessary suction.

Next, remove the gas cap and insert one end of the tube through the hole where you would usually place the gas station nozzle. You may need to use a step stool to reach the tank. Ensure that the free end of the hose is higher than the end in the gas tank for the suction to work correctly.

Now, place the free end of the hose in your mouth and begin to suck on the end to draw the gasoline up through the tube. Be careful to suck slowly to prevent accidentally ingesting gas. When the gas is 2 inches away from your mouth, seal the end of the tube with your thumb.

Finally, lower the end of the tube into an empty gas container on the ground. Remove your thumb from the tube to start the flow of gas. To stop the flow, crimp the hose and let go to restart the flow if you need to fill another container.

Alternatively, you can use an air pump to siphon the gas. You can also remove the tank outlet hose at the filter below the driver's seat area and cycle the pump on and off with the ignition key to fill a bucket.

Please note that siphoning gas from someone else's F-150 without their permission is a criminal act.

Removing the heat shield

To remove the heat shield, you will need an impact wrench. Once your truck is safely and securely raised, crawl under the truck and locate the heat shield. You will notice two sets of bolts. One set holds the heat shield in place, and the other set holds the fuel tank in place.

First, locate the bolts that hold the heat shield in place. They will be aligned with the heat shield strap. Using your impact wrench, remove these bolts. Be careful not to remove the bolts for the tank straps before removing the heat shield.

After removing the bolts, the heat shield will start to drop. Place your knee against it to prevent it from falling on you as you wiggle it free. Once it is free, set it aside.

Lowering the fuel tank

To lower the fuel tank of your Ford F-150, you will need to spend a lot of time underneath your truck, so it is important to ensure your safety and that of others. Always be sure that your F-150 is on a flat and safe surface with the engine off before performing any DIY procedures.

Now, to lower the fuel tank, follow these steps:

Step 1: Remove the fuel from your tank

Before removing your fuel tank, you need to be sure it is empty or close to empty. In order to do this, you will need to siphon the gas out using a clear hose and air pump.

Step 2: Elevate your truck

In order to safely work beneath your F-150, your vehicle will need to be propped at least 18 inches above the ground. Use a standard jack and place it in the grooves along the frame of your truck. For trucks that are already lifted, you may have enough room to work without having to jack up your truck.

Step 3: Remove the heat shield

Once your truck is safely and securely raised, grab your impact wrench and crawl under the truck. You will find that the heat shield is protecting the fuel pump. You will also notice two sets of bolts. One set holds the heat shield in place, while the other set holds the fuel tank in place. First, locate and remove the bolts that hold the heat shield in place. Be careful not to remove the bolts for the tank straps before removing the heat shield. After removing the bolts, place your knee against the heat shield as it drops so that it doesn't fall on you. Once it is free, put it aside.

Step 4: Place two floor jacks underneath the fuel tank

Grab two floor jacks and place them underneath the fuel tank to support it as you remove its bolts. Be sure that the jacks are raised just enough to support the tank, and consider adding soft padding between the jack stand and the tank to prevent damage.

Step 5: Remove the fuel tank bolts and straps

Use an impact wrench to remove the bolts from the fuel tank. Once both straps are loosened, lower the straps and gently twist them off to avoid damaging the mounting point.

Step 6: Lower the fuel tank

Now your fuel tank should be supported only by the jack stands. Ask someone to slowly lower the stands while you hold the fuel tank. The front end won't drop right away because it is connected to the fuel fill line, so you will need to disconnect this line using a hex socket. Once the fuel fill line is disconnected, your assistant can lower the jack stands further, and you should be able to pull the fuel tank out from under the truck.

Now that you have successfully lowered the fuel tank, you can proceed to locate and clean the fuel pump module.

Disconnecting the fuel pump lines

Firstly, it is important to understand that there are two main ways to access the fuel pump on a Ford F-150: by dropping the fuel tank or removing the bed. Either method will require disconnecting the fuel pump lines from the fuel pump module.

If you have opted to remove the bed for easier access, make sure to disconnect the wiring for the tail and license plate light assemblies, and the fuel filler cap and strap that secure the filler neck to the bed. Once the bed is removed, you will have better access to the fuel pump assembly and the fuel pump module.

Now, to disconnect the fuel pump lines:

Step 1: Identify the fuel pump module, which is bolted onto the top of the fuel tank. This module is connected to the fuel lines by safety clips.

Step 2: To release the fuel lines from the module, you can use your hands to pull and release the safety clips. If they are difficult to remove, you may use an aluminium 3/8" Ford fuel line disconnect tool. Be careful when handling the fuel lines to avoid any damage.

Step 3: Once the fuel lines are disconnected, set them aside and proceed to remove the old fuel pump assembly from the fuel tank.

It is important to work carefully and safely when performing any fuel pump repairs or replacements. Always refer to a trusted repair manual or seek professional assistance if you are unsure about any steps.

Installing a new fuel pump assembly

First, ensure your Ford F-150 is on a flat and safe surface with the engine turned off. It is crucial to perform this task with the engine off to avoid any accidents. Next, drain the gas tank by siphoning the fuel out using a clear hose and an air pump. This step is crucial for safety and to avoid spills. Once the tank is empty or close to empty, you can proceed to the next step.

Now, you need to elevate your truck to access the fuel tank. Use a standard jack and place it in the grooves along the frame of your truck. Raise the vehicle to a height of at least 18 inches above the ground. If your truck is already lifted, you may not need to jack it up.

Once your truck is securely raised, crawl under it with an impact wrench. Locate the heat shield, which protects the fuel pump. You will notice two sets of bolts: one set holds the heat shield, and the other set holds the fuel tank in place. Carefully remove only the bolts for the heat shield and then take off the heat shield.

Next, place two floor jacks underneath the fuel tank to support it when you remove the bolts and straps holding it in place. You can add soft padding on top of the jacks to prevent any damage to the tank. After placing the jacks, remove the bolts and straps securing the fuel tank. Gently twist off the straps to avoid damaging the mounting point. Now, carefully lower the jacks while holding the fuel tank. It is easier to have an assistant help with this step. Midway through lowering, disconnect the fuel fill line using a hex socket.

At this point, you will see a fuel pump module bolted to the top of the fuel tank. Disconnect the fuel pump lines from this module by releasing the safety clips that connect them. You can also use an aluminum 3/8" Ford fuel line disconnect tool for this step.

Before removing the old fuel pump assembly, clean the fuel pump module with a plastic brush to prevent any dirt or dust from falling into the tank. Once cleaned, use a Sharpie pen to mark the module and the tank for proper alignment of the new pump.

Now, you can remove the old fuel pump assembly. First, unfasten the bolts attaching the module to the tank. You may need to carefully use a flathead screwdriver to pry it loose if it is stuck. Twist and lift the old assembly out of the tank.

With the old assembly removed, you can now install the new fuel pump assembly. Lower the new unit into the fuel tank, aligning it with the mark you made earlier. Secure the new assembly with the screws and reconnect the fuel lines, outlay, and relay lines, as well as the evaporative hoses.

Finally, turn on the ignition to run the fuel pump and check for any leaks before lowering your vehicle and closing up. Ensure there are no fuel leaks or odors before starting the engine and driving your Ford F-150.

This process requires careful attention to detail and safety precautions. If you are uncomfortable with any of these steps, it is best to consult a professional mechanic.

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