Replacing Fuel Pump In '96 Ford F150: Step-By-Step Guide

Changing the fuel pump on a 1996 Ford F-150 can be a complex task. The vehicle has dual tanks, each with its own fuel pump, and a fuel tank selector valve that allows for switching between the two tanks. When changing the fuel pump, it is recommended to remove the bed of the truck or drop the tank for easier access. It is also important to verify fuel pressure and check the fuel filter before replacing the pump, as other issues may be causing problems. Additionally, there are potential issues with the fuel tank selector valve, which can cause fuel to transfer between tanks when driving.

The cost of replacing a fuel pump

The average cost for a Ford F-150 Fuel Pump Replacement is between $1,332 and $1,720, but can vary from car to car. Labor costs are estimated between $230 and $290, while parts are priced between $1,102 and $1,430. This range does not include taxes and fees and does not factor in your unique location.

One source suggests that the pump alone is usually about $500, and labor costs can be estimated between $200 and $400. Another source estimates the cost to be between $800 and $1500, depending on the garage.

If you are replacing the pump yourself, you can purchase a pump for your 1996 F-150 for between $150 and $376.

Removing the bed vs dropping the tank

When it comes to changing the fuel pump on a 1996 Ford F150, there are two main options: removing the bed or dropping the tank. Here's a detailed and instructive guide to help you decide which approach to take, with a focus on the removal process for each option.

Removing the Bed:

This option involves taking off the truck bed to access the fuel pump. First, use an impact wrench to remove the six bed bolts that keep the bed in place. Next, disconnect the fuel filler cap by removing the three 7mm bolts holding it in place. Let the cap hang down. Then, climb under the truck to locate and loosen the clamp that connects the filler neck to the bed.

At this point, you need to disconnect the bed and tail lights. Slide underneath the truck bed and disconnect the wire harness for the bed lighting. You can find this by sliding to the left rear corner of the bed and looking straight up. Pull on the two connectors until they come loose. Be careful of falling dirt! Next, remove the two taillight plugs located at each corner of the back of the bed. Twist and pull them out.

Now, it's time to lift the bed off the truck. This step is easier with two strong helpers, but if you don't have any, you can use bed hooks, ropes, and a chain hoist to lift it. Once the bed is lifted, pull the truck forward and lower the bed onto a soft surface or sawhorses. With the bed removed, you'll have access to the fuel pump, which is located just behind the cab.

Dropping the Tank:

The other option is to drop the fuel tank to reach the fuel pump. This method requires siphoning gas and using a car jack and stands. You'll be spending more time underneath your vehicle, and you'll need to remove all the lines connecting the fuel tank. Start by siphoning the gas out of the tank using a clear hose and an air pump. Then, use a standard jack to elevate your truck to a height of at least 18 inches above the ground. Place the jack in the grooves along the frame.

Once the truck is securely raised, crawl under it and locate the heat shield protecting the fuel pump. You'll see two sets of bolts: one set for the heat shield and another for the fuel tank. Use your impact wrench to remove the bolts holding the heat shield in place first. As you remove the bolts, the heat shield will start to drop, so use your knee to support it as you wiggle it free.

Next, grab two floor jacks and place them under the fuel tank to support it while you remove its bolts. Make sure to pad the jacks with soft material to prevent damage to the tank. Remove the four long bolts from the fuel tank straps with your impact wrench. Once the straps are loosened, lower and twist them off carefully. Set them aside, and slowly lower the jacks while holding the fuel tank. The front end will still be connected to the fuel fill line, so you'll need to disconnect this with a 1/4 inch hex socket.

With the fuel fill line disconnected, you can fully lower the jacks and pull the fuel tank out from under the truck.

Comparison:

Both methods have their advantages and considerations. Removing the bed provides easier access to the fuel pump but may be more challenging due to the weight and size of the bed. It also requires disconnecting various components, such as lighting and fuel filler neck clamps. On the other hand, dropping the tank involves working in a tighter space and dealing with potentially rusty connections. It requires siphoning gas and working underneath the vehicle. Ultimately, the decision depends on your preferences, available tools, and the specific situation of your truck.

Testing fuel pressure

To test the fuel pressure on a 1996 Ford F150, you will need to use a fuel pressure gauge. This can be attached to the Schrader valve, which is located on the right side of the engine (passenger side) at the firewall. It looks similar to a bicycle tire valve.

Turn the key in the ignition and check the fuel pressure. If you do not see instant fuel pressure, you may have a fuel pump problem or a blockage in a filter. Normal fuel pressure should be around 50-60 PSI. If you are not reaching this pressure, it could be a sign of a faulty fuel pump or a clogged filter.

If you are experiencing low fuel pressure, there are a few things you can check. Firstly, ensure that you have replaced the fuel filter recently, as a dirty or clogged filter can affect fuel pressure. Check the fuel lines from the filter forward for any signs of kinks or damage. Disconnect the filter and the fuel rail, then try blowing compressed air through the line in both directions to check for any blockages.

If you are still experiencing low fuel pressure, it may be necessary to replace the fuel pump. However, before doing so, you can try testing the other pump if you have a dual-tank system. Additionally, ensure that you are testing the fuel pressure while the engine is running, as turning the key on and off will not provide accurate results.

Replacing the fuel filter

To replace the fuel filter on a 1996 Ford F-150, you'll first need to locate the filter. It is usually found on the frame rail near the fuel tank. Once you have located the filter, follow these steps:

• Relieve the fuel system pressure and disconnect the negative battery cable.
• Remove the fuel filter mounting bracket and the old fuel filter.
• Install a new fuel filter and secure it with the mounting bracket.
• Reconnect the negative battery cable and start the engine.
• Check for leaks and ensure that the fuel filter is secure.
• It is recommended to replace the fuel filter every 10,000 miles or once a year, whichever comes first.
• When replacing the fuel filter, it is also a good idea to inspect the fuel lines for any signs of damage or leaks.
• If you are having issues with your fuel pump, it is worth checking the fuel filter first as a clogged filter can cause similar symptoms to a faulty pump.
• Always refer to your owner's manual for vehicle-specific information and safety precautions before attempting any maintenance or repairs.

Locating the fuel tank selector valve

To locate the fuel tank selector valve on a 1996 Ford F-150, look under the driver's side of the vehicle, mounted on the frame rail. This is where you will find the reservoir fuel tank selector valve.

The fuel tank selector valve regulates and permits fuel movement between the front and rear tanks, using a selector switch. When one valve is switched on, the other is closed, and vice versa.

If you are experiencing fuel system problems, such as electrical problems with the coil, internal leaks from the valves, or external fuel leaks, you may have an issue with your fuel tank selector valve.

You can purchase replacement selector valves online and at auto parts stores. When replacing the valve, ensure you are working in a well-ventilated area, free from fire risks.

Frequently asked questions