Replacing Fuel Pump In 2002 Ford F250: Step-By-Step Guide

Changing the fuel pump on a 2002 Ford F250 is a moderately complicated job that can be done at a dealership’s service department or by a seasoned mechanic. The fuel pump is located inside the fuel tank and can be accessed by removing the truck bed or the fuel tank. Before attempting to replace the fuel pump, it is important to ensure that the F-150 or Super Duty is on a flat and safe surface with the engine off, and to drain the gas tank. When removing the fuel tank, it is necessary to siphon the gas and use a car jack and stands to elevate the truck. The heat shield and fuel tank must be removed, and all lines connecting the fuel tank to the truck must be disconnected. When removing the truck bed, the bed bolts, fuel filler cap, filler neck clamp, and wire harnesses for the bed and tail lights must be disconnected before lifting the bed off the truck. Once access to the fuel pump is gained, the old fuel pump assembly can be removed and replaced with a new one.

Siphoning gas and removing the fuel tank

Siphoning Gas:

• Before removing the fuel tank, it is important to ensure that it is empty or close to empty.
• Use a clear hose and an air pump to siphon the gas out of the tank. There are videos available online that demonstrate the proper steps for this process.

Removing the Fuel Tank:

• This step requires the use of a car jack and several stands. You will also need to remove all the lines connecting the fuel tank to the truck.
• Use a 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 of your truck. If your truck is already lifted, you may have enough room to work without jacking it up.
• Crawl under the truck and locate the heat shield, which protects the fuel pump. You will also see 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 holding the heat shield in place. Be careful not to remove the bolts for the tank straps.
• Once the heat shield bolts are removed, the heat shield will start to drop. Place your knee against it to prevent it from falling on you as you wiggle it free. Then, set it aside.
• 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 using soft padding between the jack stand and the tank to prevent damage.
• Use an impact wrench to remove the four long bolts from the fuel tank. Once both straps are loosened, lower and twist them off gently to avoid damaging the mounting point.
• Now, the fuel tank should only be supported by the jack stands. Slowly lower the stands while holding the fuel tank. The front end won't drop right away because it is connected to the fuel fill line, which can be disconnected using a 1/4 inch hex socket.
• Once the fuel fill line is disconnected, slowly lower the jack stands and pull the fuel tank out from under the truck.

At this point, you can move on to locating and cleaning the fuel pump module, which is the same process for both options (removing the fuel tank or removing the bed).

Disconnecting the fuel filler cap

Tools Required:

• Impact wrench
• Flathead screwdriver
• 7mm bolts

Procedure:

Step 1: Using your impact wrench, remove the six bed bolts that secure the bed of your truck. This will be the first step in gaining access to the fuel filler cap and the underlying components.

Step 2: Now, locate the three 7mm bolts that hold the fuel filler cap in place. These bolts need to be loosened, and once they are, let the cap hang down. Be careful not to drop or misplace these small bolts.

Step 3: Climb down under the truck, just beneath the gas cap. Here, you will find a clamp that securely connects the filler neck to the bed of your truck. Loosen this clamp; this will allow the filler neck to become loose from the bed, providing the necessary access for the next steps.

Step 4: For this step, you will need to slide further underneath the truck bed. You will need to disconnect the wire harness for the bed lighting. To locate this, slide over to the left rear corner of the bed and look straight up. You should see two connectors that you can pull to loosen. Be cautious, as dirt may fall into your eyes! Once loosened, let the two ends of the wire harness hang loose.

Step 5: Next, you need to remove the taillight plugs. These are located at each corner of the back of the bed. Simply twist and pull them out.

By following these steps, you will successfully disconnect the fuel filler cap, allowing you to access and work on the fuel pump of your 2002 Ford F250. Remember to work safely and wear the appropriate protective gear, especially eye protection, to avoid any injuries.

Removing the filler neck clamp

To remove the filler neck clamp, you will need to first remove the bed of your 2002 Ford F250. This is a relatively simple process, but it will require the help of two strong friends or, alternatively, bed hooks, two ropes, and a chain hoist to lift the bed.

Start by using an impact wrench to remove the six bed bolts. Then, remove the three 7mm bolts that hold the filler cap in place. After you loosen the cap, let it hang down.

Next, climb down under the truck just beneath your gas cap. Here, 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.

Now that you have removed the filler neck clamp, you can continue with the next steps to replace the fuel pump.

Disconnecting the bed and tail lights

Step 1: Remove the bed bolts

Using an impact wrench, remove the six bolts that secure the bed of the truck. These bolts will be located on the bed of the truck, and removing them is the first step in detaching the bed from the truck's frame.

Step 2: Disconnect the fuel filler cap

Locate the three 7mm bolts that hold the filler cap in place and loosen them with a suitable tool. This will allow the filler cap to hang down, providing access to the components below.

Step 3: Remove the filler neck clamp

Climb underneath the truck, just below the gas cap. Here, you will find a clamp that connects the filler neck to the bed of the truck. Loosen this clamp to free the filler neck from the bed.

Step 4: Disconnect the bed and tail lights

Slide underneath the truck bed and locate the wire harness for the bed lighting. This can be found in the left rear corner of the bed. Pull on the two connectors until they come loose. Be careful, as dirt may fall into your eyes. Move the wire harness out of the way and let it hang loose.

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

Step 5: Lift the bed off the truck

With the bolts, filler cap, neck clamp, and lights disconnected, it's now time to remove the bed. Grab a friend and position yourselves on each side of the bed. Lift the bed off the truck and pull the truck forward. Lower the bed onto a soft surface or a set of sawhorses.

With the bed and tail lights disconnected, you can now access the fuel pump module and proceed with the fuel pump replacement.

Lifting the bed off the truck

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 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 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. Be careful of falling dirt! 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

With the help of two friends, grab a side of the truck bed and lift it off the truck. If you don't have two strong friends available, you can 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.

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