Replacing Electric Fuel Pump In Ford F350: Step-By-Step Guide

If your Ford F350 is showing a sudden drop in fuel economy, it could be a sign of a faulty fuel pump. Luckily, you can replace it yourself. Before you start, make sure your F350 is on a flat and safe surface, and that the engine is off. You will also need to drain the gas tank. You can either remove the fuel tank or the truck bed to access the fuel pump. Removing the fuel tank requires siphoning gas and using a car jack and stands. You will also need to remove all lines connecting the fuel tank to the truck. Removing the truck bed involves removing bolts, disconnecting the bed and tailgate lighting, and removing wire harnesses. Once you have accessed the fuel pump, you can clean the module and install a new one.

Removing the fuel tank

This step requires siphoning gas and using a car jack and several stands. You will also be spending a lot of time underneath your vehicle and you will need to remove all lines that connect the fuel tank to the truck itself. The biggest difficulty with this option is that some of the connections might be very rusty and tough to loosen.

Step 1: Remove fuel from your tank

Before removing your fuel tank, you will 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. The second set holds the fuel tank in place. You first want to locate those that hold the heat shield. They will be aligned with the heat shield strap.

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 as you remove it. Place your knee against it so it doesn't fall on you as you wiggle it free. Once it is free, put it aside.

Step 4: Remove the fuel tank

Grab two floor jacks and place them underneath the fuel tank. You will need these to support the fuel tank as you remove its bolts. Be sure that the jacks are raised just enough to support the tank. It's also a good idea to insert some soft padding between the jack stand and the tank to prevent damage.

Once again, use your impact wrench to remove the four exceptionally long bolts from the fuel tank. Once both straps are loosened, lower the straps and twist them off. Don't force them or you will wind up ruining the mounting point. Set the two straps and the bolts to the side.

Now your fuel tank should be supported only by the jack stands. Ask somebody 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. You will need a 1/4 inch hex socket to remove this connection.

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.

Removing the bed

If you don't have the tools, jack stands, or inclination to get under your truck and remove the fuel tank to get to your fuel pump, you may prefer to remove your truck bed instead. This is a simple process that requires you to remove the bolts that are keeping it in place, disconnect the bed and tailgate lighting, remove the wire harnesses for the bed lighting and tail light plugs, and the fuel filler cap and fuel filler neck clamp. You will also need the help of two strong friends to lift the bed off of your truck, or you can use bed hooks, two ropes, and a chain hoist to lift the bed.

Step 1: Remove the bed

Climb onto the bed of your truck and use your impact wrench to remove the six bed bolts.

Step 2: Disconnect the fuel filler cap

Remove the three 7mm bolts that hold the filler cap in place. After you loosen the cap, let it hang down.

Step 3: Remove the filler neck clamp

Climb down under the truck just beneath your gas cap. You will find a clamp that connects the filler neck to the bed of your truck. Loosen the clamp so that the filler neck is loose from the bed.

Step 4: Disconnect bed and tail lights

Slide further underneath your truck bed and disconnect the wire harness for the bed lighting. To find it, slide over to the left rear corner of the bed and look straight up. Pull on the two connectors until they come loose. Watch out for falling dirt, which will get in your eyes if you don't wear goggles! Slide the two ends of the wire harness out of the way and let them hang loose.

Then, remove the two taillight plugs. They are located at each corner of the back of the bed. Twist them and pull them out.

Step 5: Lift the bed off the truck

This is where having a couple of strong friends comes in handy. Each one of you should grab a side and lift the bed off the truck. If you don't have two strong friends available, you can always use bed hooks, two ropes, and a chain hoist to lift the bed. Once it is lifted, pull the truck forward and lower the bed onto a soft surface or several sawhorses.

Locating and cleaning the fuel pump module

To locate and clean the fuel pump module of your Ford F350, you have two options: removing the fuel tank or removing the bed.

Option 1: Removing the Fuel Tank

• Siphon the gas from the tank using a clear hose and an air pump.
• Jack up your truck and place it on stands.
• Crawl under the truck and use an impact wrench to remove the heat shield. Be careful not to remove the bolts for the tank straps before removing the heat shield.
• Place two floor jacks underneath the fuel tank to support it while you remove its bolts.
• Remove the four long bolts from the fuel tank using an impact wrench.
• Lower the straps and twist them off gently to avoid damaging the mounting point.
• Slowly lower the jack stands while holding the fuel tank.
• Disconnect the fuel fill line using a 1/4 inch hex socket.
• Pull the fuel tank out from under the truck.

Option 2: Removing the Bed

• Remove the six bed bolts using an impact wrench.
• Disconnect the fuel filler cap by removing the three 7mm bolts holding it in place.
• Loosen the clamp connecting the filler neck to the bed of the truck.
• Crawl under the truck and disconnect the wire harness for the bed lighting by pulling on the two connectors.
• Remove the two taillight plugs located at each corner of the back of the bed.
• Lift the bed off the truck with the help of two strong people or using bed hooks, ropes, and a chain hoist.
• Whether you removed the fuel tank or the truck bed, look for the round fuel pump module bolted onto the top of the fuel tank.
• Disconnect the fuel outlay, relay lines, and evaporative hoses from the module. Use a 3/8" Ford Fuel Line Disconnect Tool for hard-to-remove fuel lines.
• Clean off dust and dirt from the top of the module using a plastic brush to prevent debris from falling into the tank.
• Mark a spot on the module and the tank with a Sharpie pen to ensure proper alignment when installing the new pump.
• Remove the bolts attaching the fuel pump module to the tank using an 8mm wrench.
• Carefully pry the module up with a flathead screwdriver if it is stuck to the rubber seal.
• Lift the assembly out of the tank.
• Inspect the individual parts of the module, including the fuel pump, fuel sender, and strainer, to determine if specific parts need to be replaced.
• Install a new fuel pump assembly, aligning it with the mark made earlier.
• Reconnect the outlay, relay lines, and evaporative hoses.

Now, you can proceed to reinstall the fuel tank or the truck bed, connecting all the necessary components and ensuring proper alignment.

Removing the old fuel pump assembly

Before removing the old fuel pump assembly, ensure that your Ford F-350 is on a flat and safe surface, with the engine off. It is also important to note that you will need to drain the gas tank before making any repairs.

First, you will need to remove the fuel from your tank. This can be done by siphoning the gas out using a clear hose and an air pump. Once your tank is empty or close to empty, you can move on to the next step.

Next, you will need to elevate your truck. Use a standard jack and place it in the grooves along the frame of your truck. Raise your 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.

Now, grab your impact wrench and crawl under the truck. Locate the heat shield, which is protecting the fuel pump. You will also see two sets of bolts—one set holds the heat shield in place, while the other set holds the fuel tank in place. Remove the bolts for the heat shield, being careful not to remove the bolts for the tank straps. As you remove the bolts, the heat shield will start to drop, so place your knee against it to prevent it from falling on you. Once the heat shield is removed, set it aside.

The next step is to remove the fuel tank. Place two floor jacks underneath the fuel tank to support it as you remove its bolts. Make sure the jacks are raised just enough to support the tank, and consider inserting some soft padding between the jack stand and the tank to avoid any damage. Use your impact wrench to remove the four long bolts from the fuel tank. Once both straps are loosened, lower and twist them off gently, being careful not to force them and ruin the mounting point. Set the straps and bolts aside.

At this point, your fuel tank should only be supported by the jack stands. Slowly lower the stands while holding the fuel tank. The front end of the tank won't drop right away because it is connected to the fuel fill line, so you will need to use a 1/4 inch hex socket to remove this connection. Once the fuel fill line is disconnected, you can fully lower the jack stands and pull the fuel tank out from under the truck.

Now, locate the fuel pump module. Whether you removed the fuel tank or the truck bed, the fuel tank can be found just behind the cab. Looking down at the tank, you will see a round fuel pump module bolted on top. Before removing the module, disconnect the fuel outlay and relay lines, as well as the evaporative hoses, from the module. Use a plastic brush to clean off any dust or dirt from the top of the module to prevent it from falling into the tank when you remove it.

Now, you are ready to remove the old fuel pump assembly. Use an 8mm wrench to remove the six bolts that attach the gas pump module to the tank. If the unit is stuck to the rubber seal underneath, carefully use a flathead screwdriver to pry it up. Then, lift the assembly out of the tank. The fuel pump module is composed of several parts, including the fuel pump, fuel sender, and strainer. If you know that a specific part is not functioning properly, you may want to replace just that individual part. However, if the pump is old, it is advisable to replace the entire unit with a new one.

Installing the new fuel pump assembly

Now that the old unit is out, you will need to get the new fuel pump assembly ready for installation. Check that you have the correct part for your Ford F350 and inspect the new assembly for any signs of damage.

Next, carefully lower the new fuel pump assembly into the fuel tank, ensuring that it is aligned with the mark you made earlier. This step may require some wiggling and adjustment to get it into the correct position. Once you are satisfied with the alignment, begin securing the assembly by screwing in the bolts. Tighten these bolts with an 8mm wrench, ensuring they are secure but not overtightened.

Reconnect the fuel outlay and relay lines, as well as the evaporative hoses, to the new fuel pump assembly. Ensure that all connections are secure and tight to prevent any leaks.

Finally, you will need to reassemble the parts of your Ford F350 that you removed to access the fuel tank. If you removed the truck bed, reconnect the lights, gas fuel filler cap, and neck clamp. If you removed the fuel tank, reconnect all straps and bolts and reattach the fuel fill line.

With the new fuel pump assembly installed and your Ford F350 reassembled, you can start the engine and check for any leaks or unusual noises. If everything looks and sounds good, you have successfully replaced the fuel pump!

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