Replacing Fuel Pump In 2010 F150: Step-By-Step Guide

If your Ford F-150 or Super Duty is struggling to fire up its engine or is experiencing strange idling, it could be that your fuel pump needs replacing. This is a complex task that requires safety precautions, such as ensuring your vehicle is on a flat and safe surface and that the engine is off. You will also need to drain the gas tank before making any repairs. There are two options for accessing the fuel pump: removing the fuel tank or removing the bed of the truck. Removing the fuel tank is a challenging process that involves siphoning gas and using a car jack and stands, as well as spending a lot of time underneath the vehicle. On the other hand, removing the bed of the truck is a more straightforward process but requires the help of two strong friends or equipment like a chain hoist to lift the bed.

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. 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.

Using a car jack and stands

To replace the fuel pump in your 2010 F150, you will need to remove the fuel tank and work underneath the vehicle. This will require the use of a car jack and stands to elevate the truck and provide access to the fuel pump. Here is a step-by-step guide on using a car jack and stands to replace the fuel pump:

Step 1: Prepare the Vehicle

Before you start, ensure your F-150 is on a flat and safe surface with the engine off. It is crucial to perform this task on level ground to maintain stability while the vehicle is elevated. Additionally, the gas tank should be close to empty to reduce the weight and make it safer to work underneath the vehicle.

Step 2: Elevate the Truck

Place a standard car jack in the grooves along the frame of your truck. Raise the vehicle until it is propped at least 18 inches above the ground. This height will provide sufficient clearance to work underneath the truck safely. If your truck is already lifted, you may not need to jack it up further.

Step 3: Remove the Heat Shield

Once the truck is securely raised, crawl under the vehicle and locate the heat shield. The heat shield is in place to protect 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. Use an impact wrench to 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 removed, set the heat shield aside.

Step 4: Support the Fuel Tank

Grab two floor jacks and place them underneath the fuel tank. Ensure the jacks are raised just enough to support the tank securely. It is recommended to insert some soft padding between the jack stand and the tank to prevent any damage.

Step 5: Remove Fuel Tank Bolts

With the jacks in place, use your impact wrench to remove the long bolts from the fuel tank. Once the straps are loosened, carefully lower and twist them off without forcing them, as this can damage the mounting point. Set the straps and bolts aside.

Step 6: Lower the Fuel Tank

At this point, the fuel tank should be supported only by the jack stands. Slowly lower the jack stands while holding the fuel tank. The front end of the tank won't drop immediately due to the connection 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, you can lower the jack stands further and pull the fuel tank out from under the truck.

Step 7: Access the Fuel Pump

With the fuel tank removed, you can now access the fuel pump for replacement. Follow the remaining steps in the fuel pump replacement guide to complete the process.

Remember to exercise extreme caution when working underneath a vehicle, and ensure the vehicle is securely supported by the jacks and stands before proceeding.

Disconnecting the fuel tank

Step 1: Remove fuel from the tank

Before you begin, ensure that your work area is well-ventilated and that you are wearing appropriate safety gear, including gloves and eye protection. To start, you will need to siphon the gas out of the fuel tank using a clear hose and an air pump. This step is crucial as it helps reduce the risk of fire and explosion when working with the fuel system.

Step 2: Elevate your truck

In order to safely work underneath your F-150, you will need to elevate the vehicle. Use a standard car jack and place it in the grooves along the frame of your truck. Raise the vehicle until it is at least 18 inches above the ground. If your truck is already lifted, you may not need to jack it up further.

Step 3: Remove the heat shield

Once your truck is securely raised, crawl under the vehicle and locate the heat shield. The heat shield is in place to protect the fuel pump. 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. Use an impact wrench to remove the bolts for the heat shield, being careful not to remove the bolts for the tank straps. Once the bolts are removed, slowly remove the heat shield and set it aside.

Step 4: Support and remove the fuel tank

Place two floor jacks underneath the fuel tank to support it while you remove its bolts. Make sure the jacks are raised just enough to support the tank, and consider placing soft padding between the jacks and the tank to prevent damage. Use an impact wrench to remove the long bolts from the fuel tank straps. Once the straps are loosened, carefully lower and twist them off, being careful not to force them as this may damage the mounting point. Set the straps and bolts aside.

At this point, the fuel tank should be supported only by the jack stands. Slowly lower the stands while holding the fuel tank. The front end of the tank will not drop immediately as it is connected to the fuel fill line. Use a 1/4 inch hex socket to disconnect the fuel fill line. Once this connection is released, the fuel tank can be carefully lowered and pulled out from under the truck.

Remember to work cautiously and seek professional advice or assistance if you are unsure about any part of the process.

Replacing the fuel pump assembly

Option 1: Removing the fuel tank

Step 1: Remove fuel from the tank

Before removing the fuel tank, use a clear hose and air pump to siphon the gas out.

Step 2: Elevate your truck

Use a car jack to raise your truck at least 18 inches above the ground. Place the jack in the grooves along the frame of your truck.

Step 3: Remove the heat shield

Using an impact wrench, remove the bolts holding the heat shield in place. Be careful not to remove the bolts for the tank straps. Once the bolts are removed, use your knee to support the heat shield as you wiggle it free.

Step 4: Remove the fuel tank

Place two floor jacks underneath the fuel tank to support it as you remove its bolts. Ask someone to slowly lower the jacks while you hold the fuel tank. Once the jacks are lowered, pull the fuel tank out from under the truck.

Option 2: Removing the bed

Step 1: Remove the bed

Use an impact wrench to remove the six bed bolts.

Step 2: Disconnect the fuel filler cap

Remove the three 7mm bolts holding the filler cap in place and let it hang down.

Step 3: Remove the filler neck clamp

Climb under the truck and loosen the clamp connecting the filler neck to the bed.

Step 4: Disconnect the bed and tail lights

Slide under the truck bed and disconnect the wire harness for the bed lighting. Remove the two taillight plugs located at each corner of the bed.

Step 5: Lift the bed off the truck

With the help of two strong friends, lift the bed off the truck. Alternatively, use bed hooks, two ropes, and a chain hoist to lift the bed.

Final steps:

Step 6: Locate and clean the fuel pump module

Whether you removed the fuel tank or the truck bed, the rest of the process is the same. Locate 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 plastic brush to clean off any dust and dirt from the module and tank.

Step 7: Remove the old fuel pump assembly

Use an 8mm wrench to remove the six bolts attaching the fuel pump module to the tank. Carefully use a flathead screwdriver to pry up the assembly if it is stuck to the rubber seal. Lift the assembly out of the tank.

Step 8: Install the new fuel pump assembly

Drop the new unit into the fuel tank, aligning it with the mark you made. Replace the screws and reconnect the outlay, relay lines, and evaporative hoses.

Step 9: Put your truck back together

If you removed the bed, reinstall it and reconnect the lights, gas fuel filler cap, and neck clamp. If you removed the fuel tank, put it back in and reconnect all straps, bolts, and the fuel fill line.

Reattaching the fuel tank

To reattach the fuel tank of your 2010 F150, you will need to follow the steps outlined below:

• Place the fuel tank back underneath the truck, ensuring it is supported by jack stands. Ask an assistant to slowly lower the jack stands while you carefully hold the fuel tank in place.
• Once the fuel tank is in position, reconnect the fuel fill line using a 1/4 inch hex socket.
• Secure the fuel tank by reattaching the four exceptionally long bolts (13mm) to the fuel tank straps. Ensure the bolts are tightened securely, but be careful not to force them as this may damage the mounting point.
• Reattach any other disconnected components, such as the heat shield and its bolts, and lower the truck from the jack.
• Reconnect the truck bed if it was removed, ensuring all bolts, lights, gas fuel filler cap, neck clamp, and wire harnesses are securely connected.

By carefully following these steps, you can safely reattach the fuel tank of your 2010 F150. It is important to work with an assistant and take the necessary precautions when working underneath a vehicle.

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