Replacing The Fuel Pump In A Classic 440 Engine

If you're looking to change the fuel pump on a 1978 440, you'll need to be aware of a few things. Firstly, there is a push rod inside the housing that you'll need to be careful with. When you take out the fuel pump, the push rod will likely fall down, and you'll need to push it back up before installing the new pump. You can also try pulling out the hex plug, sliding out the push rod, and applying some grease to it to help hold it in place. Additionally, make sure to change the rubber hose that feeds the pump, as well as the rubber hoses at the top of the fuel tank if you're still not getting gas to the carb. Finally, when it comes to the fuel lines, it's recommended to change them to 3/8 inch and install a pusher electric fuel pump close to the tank to pressurize the line up to the mechanical pump.

Removing the fuel pump

To remove the fuel pump from a 1978 440, you will need to take the following steps:

Firstly, it is recommended to remove the alternator to make the process easier. There is no need to access the fuel pump from below, as there is not much room to work with.

Now, you need to be aware of the push rod that actuates the lever inside the fuel pump. When you remove the fuel pump, the push rod will likely fall down. This is normal, and you can simply push it back up with your finger before installing the new pump. If it keeps falling down, you can try applying some grease to it to help hold it in place.

To access the push rod, you will need to remove the hex plug/pipe plug located below the fuel pump. Some sources recommend removing the push rod entirely, while others suggest leaving it in place. If you choose to leave it, make sure to reinstall the hex plug to prevent oil leaks.

With the push rod managed, you can now remove the fuel pump itself. Be aware that the pump may not sit flush against the block due to the eccentric on the cam. Just slowly tighten the bolts to secure it in place.

And that's it! You have now successfully removed the fuel pump from your 1978 440. Remember to take your time and be careful, especially with the push rod, to avoid any complications.

Removing the hex bolt

Identifying the Hex Bolt:

Before attempting to remove the hex bolt, it is important to correctly identify it. A hex screw has a raised hexagonal head, and it is typically driven using a hexagonal socket wrench or a socket with a drill. This is different from an Allen screw, which has a hexagonal slot that requires an Allen wrench for removal.

Tools and Techniques for Removal:

There are several tools and techniques you can use to remove a hex bolt:

• Hexagonal Socket Wrench: If the bolt is not stripped, try using a hexagonal socket wrench that fits the head tightly. This is the standard method for removing hex bolts.
• Regular Wrench or Pliers: In some cases, you may be able to remove the bolt using a regular wrench or a pair of pliers. This approach may work if the bolt head has not been damaged.
• Grinding a Slot: If the bolt is stripped or stuck, you can use a rotary tool with a grinding wheel to grind a slot in the head of the bolt. Once the slot is created, you can use a flathead screwdriver to turn and remove the bolt.
• Locking Pliers: Another option is to use locking pliers. Clamp the pliers onto the bolt head and turn it counterclockwise to remove it. This method can be effective, especially if the bolt head is raised above the surface.
• Screw Extractor: If the bolt is severely stripped or stuck, you may need to use a screw extractor. Drill a hole in the centre of the bolt head using an ordinary drill bit. Then, insert the screw extractor and operate the drill in reverse to back the bolt out. This method is often effective when other techniques have failed.
• Lubrication: Before attempting any of these techniques, it is recommended to apply a spray lubricant to the bolt. This will help loosen the bolt and make it easier to turn.

Additional Tips:

• Alternating Techniques: If one technique is not working, don't be afraid to try another. Sometimes, a combination of methods may be necessary to successfully remove a stubborn bolt.
• Clean and Debris-Free: Ensure that the area around the bolt is clean and free of debris. This will help prevent any foreign objects from falling into the engine compartment and causing further issues.
• Safety First: Always wear appropriate safety gear, such as gloves and eye protection, when working on your vehicle. This will help protect you from injury and keep you comfortable during the removal process.
• Refer to Manual: If you have access to the vehicle's service manual, refer to it for any specific instructions or diagrams related to fuel pump maintenance and bolt removal.

Remember to work patiently and carefully, as forcing the bolt can lead to further damage. Take your time, use the appropriate tools, and follow the provided instructions to increase your chances of success in removing the hex bolt.

Checking the push rod for wear

When checking the push rod for wear, it is important to inspect the rod for any signs of damage or abnormality. The push rod in a 1978 440 engine is responsible for actuating the lever on the inside of the fuel pump, ensuring the smooth operation of the fuel delivery system. Over time, this component can wear down and affect the engine's performance.

To check for wear, begin by locating the push rod. It is situated inside the housing of the fuel pump and can be accessed by removing the hex plug below the pump. Once accessed, carefully remove the push rod and inspect it for any signs of wear or damage. Pay close attention to the length of the rod, as it can wear down over time, impacting the function of the fuel pump. Measure the rod to ensure it meets the specified length for your engine.

Additionally, examine the surface of the push rod for any signs of concavity or mushrooming. This can occur due to prolonged use or if the camshaft's fuel pump lobe is not hardened correctly. A worn or damaged push rod can cause difficulty in starting the engine, hesitation, and a lagging response from the engine.

If you notice any signs of wear or damage, it is recommended to replace the push rod with a new one. You can source replacement push rods from automotive stores or speciality vendors, ensuring you select one made from durable materials such as brass, bronze, or hardened steel.

To prevent future issues, it is advisable to regularly inspect and maintain the push rod. This includes greasing the rod to ensure it stays in place and functions smoothly. By following these steps, you can effectively check the push rod for wear and ensure the optimal performance of your 1978 440 engine.

Installing a new pump

To install a new fuel pump on a 1978 440, follow these steps:

Firstly, take off the alternator to make the process easier. You will then need to remove the old fuel pump. When you do this, the push rod will likely fall down. This is what the hex plug below the fuel pump is for. Before installing the new pump, use your finger to push the push rod back up. If it keeps falling down, you can try pulling out the hex plug, sliding out the push rod, applying grease to it, and then sliding it back in.

Next, take your new fuel pump out of its box. With the pump, there should be a gasket. Put a slight coat of gasket sealer on one side of the gasket. This will allow you to stick the gasket to the engine block, making it easier to install the pump. Make sure there is no gasket stuck to the engine block. If there is, you will need to clean it off to get a proper seal.

Now you are ready to reinstall the fuel pump, making sure to position the pump arm under the cam or push rod. Reinstall the mounting bolts and tighten them. Now you can install the outlet line onto the pump, making sure to use two wrenches when tightening the fitting. Finally, install the inlet line using a hose clamp.

And that's it! You've installed a new fuel pump on your 1978 440.

Changing the rubber hose

Gather the Necessary Tools and Materials:

• Replacement rubber fuel hose
• Fuel hose clamps
• Screwdriver
• Pliers
• Knife
• Floor jack
• Jack stands
• Vice grips
• Fuel-resistant gloves
• Eye protection
• Rags or towels
• Plastic sheet
• Combustible gas detector
• Fuel hose quick disconnect kit
• Fuel transfer tank with pump
• Ratchet with metric and standard sockets
• Wheel chocks
• Nine-volt battery saver (optional)

Prepare Your Vehicle:

Park your vehicle on a flat, hard surface and engage the parking brake. Place wheel chocks around the front tires and use a floor jack to lift the rear of the vehicle. Support the vehicle with jack stands and remove the fuel tank straps. Place a transmission jack under the fuel tank and lower it far enough to access the rubber fuel hose.

Remove the Old Rubber Hose:

Locate the rubber fuel hose connected to the fuel pump. Place a drip pan or towel underneath to catch any leaking fuel. Remove the hose clamps that hold the rubber hose in place, using a screwdriver or wrench. Carefully pull the rubber hose off the fuel pump and fuel line, using a blade if necessary.

Install the New Rubber Hose:

Slide the new rubber hose onto the fuel pump and fuel line. Ensure that the hardware will face you when the hose is in place. Position the new hose clamps over the new rubber hose, keeping them loose for now. Tighten the hose clamps with a screwdriver until the hose is firmly in place.

Final Steps:

Reconnect the negative terminal on the battery and pressurize the fuel system by returning the fuel pump fuse in the fuse box. Start the engine and inspect for any fuel leaks. If there are no leaks, lower the vehicle, remove the wheel chocks, and take the vehicle for a test drive to ensure proper fuel flow.

Additional Tips:

• Always work in a well-ventilated area to avoid gas fumes, and have a fire extinguisher nearby.
• Do not use tools that could create sparks.
• Wear fuel-resistant gloves and eye protection for safety.
• Consult your vehicle's service manual for specific information about fuel hose replacement.

Frequently asked questions