Replacing The Fuel Pump In Your F350: A Step-By-Step Guide

Changing the fuel pump on a Ford F350 can be a challenging task, but with the right tools and guidance, it is certainly achievable. The fuel pump is responsible for directing fuel from the tank to the carburetor, and a faulty pump can cause various issues such as difficulty firing up the engine, strange idling, reduced fuel economy, and more. Before beginning the replacement process, it is crucial to ensure that your F-150 or Super Duty is on a flat and safe surface with the engine turned off. Additionally, draining the gas tank is necessary for this repair. There are two main options for accessing the fuel pump: removing the fuel tank or removing the truck bed. Removing the fuel tank involves siphoning gas, using a car jack and stands, and working underneath the vehicle to remove the connections to the fuel tank. On the other hand, removing the truck bed requires disconnecting lighting, harnesses, and fuel filler components, and then lifting the bed off the truck, which may require the help of a couple of strong friends or special equipment. Once access to the fuel pump is gained, the process of replacing it is similar for both options. The fuel pump module is bolted onto the fuel tank and needs to be carefully removed, cleaned, and replaced with a new one. It is important to properly align the new pump and reconnect all the necessary components. Finally, the truck bed or fuel tank needs to be reinstalled, ensuring all connections are secure.

Removing the fuel tank

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

Firstly, you will need to siphon the gas out of your tank using a clear hose and air pump. Your tank will need to be empty or close to empty before removal.

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.

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, and the second set holds the fuel tank in place. 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.

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.

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 in order to get to your fuel pump, you may prefer to remove your truck bed instead. This is a simple process, but you will need the help of two strong friends to lift the bed off your truck.

First, use a flathead screwdriver 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. 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, disconnect the 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. Wear goggles, as dirt will likely fall into your eyes! Let the two ends of the wire harness 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.

Now, grab a side of the bed and, with the help of a friend, 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

Locating the fuel pump module on a Ford F350 depends on the year and model of the vehicle. For a 2011 F350 gasoline model, the fuel pump module is located on the frame rail on the driver's side, right under the door. It is much smaller than the F150 module and made of plastic. It looks like a big relay.

For a 2006 Expedition/Explorer, the fuel pump module is mounted on the left rear frame rail, just behind the left rear tire. The mounting can collect water, mud, and debris, which can cause corrosion in the module's aluminum body.

For a 2008 Ford E-350, the fuel pump driver module is located on top of the fuel tank.

For a 2001 F350 with a V-10 single plastic fuel tank, the fuel pump is clipped to the bottom of the tank. To remove it, locate the two tabs sticking up from the plastic housing. These are the exposed parts of a pair of plastic latches that hold the pump housing in the plastic cup attached to the tank. Follow the latch down and pop it loose from the recess, then pull the pump housing up and work the filter sock out of its slot.

To clean the fuel pump module, first remove the fuel pump by following the steps outlined above. Then, use a clean, dry cloth to wipe down the module, taking care to remove any dirt, debris, or corrosion that may be present. Reinstall the fuel pump and module, ensuring that all connections are secure.

Removing the old fuel pump assembly

To remove the old fuel pump assembly, you will need to locate the fuel pump module. This can be found bolted onto the top of the fuel tank. Before removing the bolts, you will need to disconnect the fuel outlay and relay lines from the module, as well as the evaporative hoses. These are fastened by safety clips which you can pull and release to free them from the module. Alternatively, you can use a 3/8" Ford Fuel Line Disconnect Tool to detach any hard-to-remove fuel lines.

Once the lines are disconnected, use a plastic brush to clean off any dust or dirt from the top of the module, so that it doesn't fall into the tank when you remove it. Then, use a Sharpie pen to mark a spot on the module and the tank, so that you can align the new pump properly when installing it.

After marking the alignment, use an 8mm wrench to remove the bolts attaching the gas pump module to the tank. Then, twist and lift the unit out. The fuel pump module may be stuck to the rubber seal underneath, so you may need to carefully use a flathead screwdriver to pry it up. Finally, 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 are a seasoned mechanic and you know which specific part is not functioning properly, you may just want to replace that individual part. However, if the pump is old, it is advisable to replace the entire unit with a brand new one.

Installing the new fuel pump assembly

Now that the old unit is out, you can start installing the new fuel pump assembly. Drop the new unit down into the fuel tank, aligning it with the mark you made earlier with your marker. Replace and tighten the screws. Reconnect the outlay and relay lines, as well as the evaporative hoses.

If you removed the truck bed, you will now need to reinstall it and reconnect the lights, gas fuel filler cap, and neck clamp. If you removed the fuel tank, put it back in, reconnecting all straps and bolts, and reattaching the fuel fill line.

Finally, start the engine and check for any leaks. Your new fuel pump is now installed, and you can enjoy improved engine performance and a smoother ride.

Frequently asked questions