Replacing Fuel Pump In Ford Pickups: Step-By-Step Guide

If you're experiencing trouble firing up your Ford pickup engine or notice strange idling while driving, it could be that your fuel pump is malfunctioning. The fuel pump is a component that can wither over time, and you will need to replace it.

Ford pickups are equipped with electric pumps, which are designed to direct fuel from the tank to the carburetor. This component is essential to the overall performance of your vehicle.

Step 1: Safety First

Always ensure your pickup is on a flat and safe surface with the engine off before performing any DIY procedures. For this task, you will also need to drain the gas tank before making any repairs.

Step 2: Choose Your Approach

You have two options to access the fuel pump: removing the fuel tank or removing the truck bed. Removing the fuel tank requires siphoning gas and using a car jack and stands. It involves spending a lot of time underneath your vehicle and removing all lines connecting the fuel tank to the truck. The difficulty lies in dealing with rusty and tough-to-loosen connections.

On the other hand, removing the truck bed is a more straightforward process. It involves removing the bolts that keep the bed in place, disconnecting the bed and tailgate lighting, and removing wire harnesses. This option may be preferable if you don't have the necessary tools for the first option or don't want to work underneath the truck.

Step 3: Accessing the Fuel Pump

Once you've chosen your approach, it's time to access the fuel pump. If you opted to remove the fuel tank, use a clear hose and air pump to siphon the gas out of the tank. Make sure to do this in a well-ventilated area and store the fuel in a safe container.

Now, elevate your truck using a jack and place it on stands to safely work underneath. Remove the heat shield by locating and unscrewing the bolts holding it in place. Be careful not to confuse these bolts with the ones securing the fuel tank.

If you chose to remove the truck bed, climb onto the bed and use an impact wrench to remove the bed bolts. Then, disconnect the fuel filler cap and the filler neck clamp located underneath the gas cap.

Step 4: Lowering the Fuel Tank

For both approaches, you will now need to lower the fuel tank to access the fuel pump. If you haven't done so already, use a jack to elevate the truck to a safe working height. Place two floor jacks underneath the fuel tank to support it as you remove the bolts and straps securing it in place. Gently lower the jacks while holding the fuel tank, and ask a helper to slowly lower the jacks as you support the tank.

Step 5: Disconnecting the Fuel Pump

At this point, you should see the fuel pump module bolted onto the top of the fuel tank. Disconnect the fuel pump lines from the module by releasing the safety clips or using a fuel line disconnect tool. Mark the current position of the fuel pump with a marker so you can align the new pump correctly.

Step 6: Removing the Old Fuel Pump

Unscrew the bolts holding the fuel pump module to the tank and carefully twist or pry out the old fuel pump assembly. You may need a flathead screwdriver to help loosen any stuck components.

Step 7: Installing the New Fuel Pump

Install the new fuel pump assembly by reversing the removal process. Ensure all connections are secure, especially the fuel lines, and reconnect the battery. Reinstall the truck bed or fuel tank, whichever you removed earlier.

And that's it! You've successfully replaced the fuel pump in your Ford pickup. Now you can enjoy improved engine performance and a smoother driving experience.

Siphoning the fuel

The next step is to remove the heat shield. This can be done with the help of an impact wrench. There are two sets of bolts, one set holding the heat shield in place and the other holding the fuel tank in place. Only the set that holds the heat shield should be removed. The heat shield should be carefully removed by placing a knee against it to prevent it from falling.

The following step is to place two floor jacks underneath the fuel tank to support it when it drops. Padding can be added on top of the jacks to prevent any damage to the tank.

The fuel tank can now be dropped by unfastening the bolts and straps holding it in place. The fuel fill line should be disconnected halfway through the process with the help of a hex socket.

The fuel pump lines should be disconnected from the fuel pump module. The module is bolted to the top of the fuel tank and the fuel lines are connected to it by safety clips. These can be released by hand or with the help of a tool.

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 with your impact wrench. 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. First, locate the bolts 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.

Supporting the fuel tank

To support the fuel tank, you will need to place two floor jacks underneath it. This will help to support the fuel tank when it drops. You can also add padding on top of the floor jacks to prevent damage to the tank.

• Get two floor jacks and place them underneath the fuel tank.
• Ensure that the jacks are raised just enough to support the tank.
• It is recommended to insert some soft padding between the jack stand and the tank to prevent damage.
• Once the jacks are in place, use an impact wrench to remove the four long bolts from the fuel tank.
• After both straps are loosened, lower the straps and twist them off gently. Avoid forcing them or you will wind up ruining the mounting point.
• 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 of the tank 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.

Disconnecting the fuel pump lines

Step 1: Prepare the necessary tools and safety measures.

Before starting, ensure you have the required tools, such as a flathead screwdriver, an impact wrench, and a clear hose and air pump for siphoning gas. It is also important to work in a well-ventilated area and take precautions to avoid any sparks or ignition sources.

Step 2: Remove the fuel tank.

The fuel pump is located inside the fuel tank, so you will need to remove the tank to access it. Place your Ford pickup on a safe lift and siphon the fuel from the tank using the clear hose and air pump. This step is crucial for safety reasons and to prevent spills.

Step 3: Identify the heat shield and fuel tank bolts.

Using your impact wrench, locate the two sets of bolts. One set holds the heat shield in place, while the other set secures the fuel tank. It is important to identify these correctly to avoid accidental removal of the wrong bolts.

Step 4: Remove the heat shield.

Unfasten only the bolts holding the heat shield in place. After removing these bolts, carefully remove the heat shield, supporting it with your knee to prevent it from falling on you. Set the heat shield aside in a safe place.

Step 5: Support the fuel tank with floor jacks.

Place two floor jacks underneath the fuel tank to support it when you remove the remaining bolts and straps. You can also add soft padding on the jacks to prevent any damage to the tank during this process.

Step 6: Remove the fuel tank bolts and straps.

Now, you can unfasten the bolts holding the fuel tank in place. Be careful not to force or break the bolts, as this can damage the mounting point. Gently twist and remove the straps to avoid any damage.

Step 7: Lower the fuel tank carefully.

With the help of an assistant, carefully lower the floor jacks while supporting the fuel tank. As you lower it, you may need to disconnect the fuel fill line using the appropriate socket. This will provide more room to work on the fuel pump and lines.

Step 8: Locate the fuel pump module and lines.

On the top of the fuel tank, you will find a fuel pump module. The fuel lines are connected to this module by safety clips. Identify these lines and clips carefully, as you will be disconnecting them in the next step.

Step 9: Disconnect the fuel pump lines.

To disconnect the fuel pump lines, you can carefully use a flathead screwdriver to release the retaining clips if they are difficult to cooperate. Alternatively, you can use an aluminum 3/8" Ford fuel line disconnect tool, which is designed for this purpose. Be gentle during this process to avoid any damage to the lines or the module.

By following these steps, you will successfully disconnect the fuel pump lines, allowing you to proceed with the next steps of changing the fuel pump in your Ford pickup.

Cleaning the fuel pump module

Before you begin the process of cleaning the fuel pump module, it is important to identify the signs of a clogged fuel pump. These signs can include engine "sputtering" or stalling, intermittent power loss, a clicking or whining noise coming from the area around the gas tank, and a drop in RPMs while driving.

Once you have identified that the fuel pump requires cleaning, follow these steps:

• Disconnect the battery: Locate the battery and disconnect the negative terminal. This is important to ensure that there is no risk of sparks or electrical current during the cleaning process.
• Locate the fuel pump: Refer to your vehicle's user manual or service manual to identify the exact location of the fuel pump. In Ford F-150 trucks, the fuel pump is located inside the fuel tank, which can be accessed by either removing the fuel tank or the truck bed.
• Prepare the work area: If you are working on a vehicle, roll down the windows. Gather the necessary tools, including a knife, a hammer, flat screwdrivers (one wide and dull), a piece of cardboard, and a fire extinguisher.
• Remove the fuel pump cover: The cover is usually made of plastic and has fragile tabs. Cut the cover carefully with a knife if necessary. Clean the area underneath the cover to prevent dirt and debris from falling into the gas tank.
• Disconnect the pump's wires and fuel line: Mark the alignment of the pump and then disconnect the wires and fuel line. You may need a screwdriver and a hammer to gently tap the retention ring loose.
• Remove the fuel pump: Slowly pull out the fuel pump, being careful not to bend the float arm. Lean the pump sideways to allow the gas inside to leak back into the tank. Cover the opening with a piece of cardboard to allow gas fumes to escape through the rolled-down windows.
• Clean or replace the coarse mesh filter: The fuel pump housing typically consists of two parts: the lower housing with the coarse mesh filter and the upper housing with the pump and electric parts. Use a narrow screwdriver to release the tabs holding the two parts together. Remove the mesh filter, which may be clogged with debris. Clean the filter with warm water or replace it with a new one. Ensure that the filter is completely dry before reassembling.
• Reassemble the fuel pump: Put the cleaned or new mesh filter back into the lower housing and push the two housing parts together until the tabs click into place. Reinstall the fuel pump by first inserting the float and then angling the pump into the opening. Be careful not to bend the float.
• Reinstall the retention ring: Start screwing the retention ring by hand and then gently hammer it clockwise until it is aligned with the mark you made on the tank. Reconnect the pump wires and the fuel line.
• Replace the fuel pump cover: If the plastic tabs on the cover are broken, you can seal it with silicone caulk using a caulking gun. Allow the silicone to dry completely before replacing any carpeting or other components.

By following these steps, you can effectively clean the fuel pump module in your Ford pickup truck.

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