Replacing The Fuel Pump In A '98 Durango: Step-By-Step Guide

Changing a fuel pump in a 1998 Dodge Durango can be a tricky task. While some people have managed to do it themselves, others have sought help from mechanics or car experts. The process involves draining and removing the fuel tank, noting the position of the indexing arrow on top of the fuel pump, and using specific tools to remove and install the lock ring and fuel pump. It is important to ensure that the fuel pump you choose is compatible with the make, model, engine size, and type of your Durango.

Prepare your vehicle for fuel pump servicing

Before you begin the process of replacing the fuel pump in your 98 Durango, there are several preparatory steps you need to take to ensure a smooth and safe procedure. Here is a detailed guide on how to prepare your vehicle for fuel pump servicing:

• Park your vehicle on a level surface: It is important to find a flat, level surface to park your car. This will ensure that your vehicle remains stable and secure during the servicing process.
• Engage the parking brake: Once you have found a suitable location, be sure to engage the parking brake to prevent any accidental movement of the vehicle.
• Turn off the engine and remove the keys: Before beginning any work on your vehicle, always turn off the engine and remove the keys from the ignition to prevent any accidental startups.
• Allow the engine to cool down: If your engine is hot, allow it to cool down before starting work. This is important for your safety and to prevent any potential fires or burns.
• Wear protective gear: Fuel pump servicing can be a messy job, so be sure to wear protective gear such as gloves and eye protection to shield your skin and eyes from any harmful chemicals or debris.
• Locate the fuel pump: Familiarize yourself with the location of the fuel pump in your 98 Durango. Refer to your vehicle's repair manual or seek guidance from an experienced mechanic if needed.
• Disconnect the battery: Before proceeding, disconnect the negative battery terminal to prevent any accidental electrical shorts during the servicing process.
• Drain and remove the fuel tank: The next step is to drain and remove the fuel tank. Place a suitable container underneath the tank to catch any spilled fuel. Use a wrench or a drain plug to drain the fuel. Once the tank is empty, remove it carefully, following the instructions in your repair manual.
• Note the position of the indexing arrow: Before removing the fuel pump, take note of the position of the indexing arrow on top of the fuel pump. This will be important when installing the new fuel pump to ensure proper alignment.

By following these steps, you will be well prepared to service the fuel pump in your 98 Durango. Remember to work in a well-ventilated area and always put your safety first.

Drain and remove the fuel tank

To drain and remove the fuel tank as part of changing the fuel pump in a 98 Durango, follow these steps:

Firstly, you will need to drain the fuel tank. This is an important step as it reduces the weight of the tank, making it easier to handle and minimising the risk of spillage. Once the tank is drained, you can begin the process of removal.

Loosen and remove any fasteners or straps holding the tank in place. Be sure to spray any fasteners with a penetrating oil beforehand to help ease the process and reduce the risk of breakage. With the fasteners removed, carefully lower the tank, being mindful of any tubes or wires connected to it. Once the tank is lowered, you can then disconnect these tubes and wires, taking care to note their positions for reassembly.

With the fuel tank removed, you can now access the fuel pump for replacement. Before doing so, take note of the position of the indexing arrow on top of the fuel pump. This will be important for aligning the new fuel pump during installation. Now, you can proceed to remove the lock ring on the fuel pump using a 1/2-inch drive breaker bar. Rotate the lock ring counter-clockwise to loosen it, and then lift the fuel pump out, being careful not to bend the float arm.

With the old fuel pump removed, you can now install the new one. Place the new fuel pump into the opening in the fuel tank, ensuring that the rubber gasket provided in the kit is properly positioned. Rotate the new fuel pump until the alignment arrow points toward the alignment mark, and check that the fitting on top of the fuel pump faces towards the driver's side. Once the new fuel pump is in the correct position, you can tighten the lock ring using the 1/2-inch drive breaker bar until all seven notches engage.

Finally, you can reinstall the fuel tank by reversing the removal process. Secure the tank in place with the fasteners or straps, and reconnect any tubes or wires that were previously disconnected.

Remove the lock ring on the fuel pump

Removing the lock ring on the fuel pump of a 98 Durango can be a challenging task, but with the right tools and techniques, it can be accomplished. Here is a step-by-step guide to help you through the process:

Prepare the Work Area:

Before beginning the removal process, it is important to take the necessary safety precautions. Work in a well-ventilated area and avoid any open flames or sparks that could ignite fuel vapors. Place a rag or a piece of cardboard over the fuel tank opening to prevent debris from falling into the tank. Wear safety goggles and gloves for protection.

Gather the Appropriate Tools:

You will need a few specialized tools to remove the lock ring effectively. Here are some options:

• Fuel tank lock ring tool: This tool is designed specifically for removing and installing fuel pump lock rings. It is made of hard steel and can be used with a 1/2" drive ratchet or breaker bar.
• Brass punch and hammer: A brass punch is less likely to create sparks than a regular metal punch. Use it with a hammer to carefully tap the lock ring.
• Flathead screwdriver and hammer: Alternatively, you can use a flathead screwdriver and a hammer to drive the ring and unlock it.
• Needle scaler: If there is significant rust buildup, a needle scaler can help break up the rust around the lock ring.
• Penetrating oil: Soak the lock ring in penetrating oil, such as PB Blaster, to help loosen it.

Remove the Lock Ring:

Now, you can begin the process of removing the lock ring:

• If there is fuel in the tank, drain it or reduce the fuel level as much as possible to lighten the tank.
• If there are any bolts or fasteners holding the tank in place, spray them with penetrating oil to make them easier to remove.
• If you are using a fuel tank lock ring tool, attach it to a 1/2" drive ratchet or breaker bar. Position the tool onto the lock ring, ensuring that it is securely engaged.
• Apply pressure to the ratchet or breaker bar and tap the tool gently with a hammer if needed to break the lock ring free.
• If you are using a brass punch and hammer or a flathead screwdriver and hammer, carefully tap the lock ring to drive it around and unlock it.
• In case of severe rust, use a needle scaler to break up rust around the lock ring before attempting to remove it.
• Work patiently and avoid using excessive force, as the fuel tank is made of thin metal and can be damaged easily.

Install a New Lock Ring:

Once the old lock ring is removed, clean the area and install a new lock ring, along with a new gasket or sealing ring, if necessary. Coat the new lock ring and pump with paint or primer to prevent rust. Reattach the fuel tank and reconnect any disconnected components.

Remember to work cautiously and follow safety protocols when working with fuel system components. With the right tools and careful techniques, you can successfully remove and replace the lock ring on your 98 Durango's fuel pump.

Remove the fuel pump

To remove the fuel pump from a 98 Durango, follow these steps:

Firstly, drain and remove the fuel tank. It is important to note the position of the indexing arrow on top of the fuel pump before removing it. This arrow is crucial for aligning the pump during installation. Once you have noted the arrow's position, you can proceed to the next step.

Now, you will need to remove the lock ring on the fuel pump. To do this, use Tool 9340 with a 1/2-inch drive breaker bar to rotate the lock ring counter-clockwise. With the lock ring removed, the fuel pump should rise up slightly. Be cautious during this process, as you do not want to bend the float arm.

At this point, the fuel pump is ready to be removed from the fuel tank. Gently lift the pump out, being careful not to damage any components, especially the float arm. Place the removed pump aside, as you will need to compare the new pump with the old one during installation to ensure proper alignment.

Before proceeding with the installation of the new fuel pump, it is important to clean the area and ensure that there is no dirt or debris that could contaminate the fuel system. It is also recommended to inspect the fuel tank for any signs of damage or corrosion. If any issues are found, address them before installing the new fuel pump.

Now, you are ready to install the new fuel pump. Refer to the kit's instructions and ensure you have all the necessary components, especially the rubber gasket for the fuel tank. Position the new fuel pump into the opening in the fuel tank, and adjust its alignment until the arrow points towards the alignment mark. This step is crucial to ensure the proper functioning of the pump and to prevent the float from contacting the side of the fuel tank.

Install the new fuel pump

To install the new fuel pump, you will need a new rubber gasket for the fuel tank, as well as tool 9340 with a 1/2-inch drive breaker bar.

First, using a new seal (gasket), position the fuel pump module into the opening in the fuel tank. Be careful not to bend the float arm while installing the new fuel pump. Next, position the lock ring over the top of the fuel pump module. Rotate the module until the embossed alignment arrow points to the centre alignment mark. This step is essential to prevent the float from contacting the side of the fuel tank. Also, ensure that the fuel fitting on the top of the pump module is pointing towards the driver's side of the vehicle.

Then, install tool 9340 into the lock ring. Install the 1/2-inch drive breaker into the tool. Tighten the lock ring (in a clockwise direction) until all seven notches have engaged. Finally, reinstall the fuel tank.

Frequently asked questions