Regan Brown
The Ford Mustang is a classic car, but even classics need a little maintenance now and then. One common issue with the 1966 Mustang is the fuel line, which can rust and leak over time. This is a problem that many owners have encountered and sought advice on, with some opting for a full fuel system replacement and others choosing to repair and replace the fuel pump. This process can be straightforward, but it can also be complex and frustrating, requiring careful attention to the fuel line's routing and the removal of multiple parts.
1966 Mustang Fuel Line Removal Characteristics and Values
| Characteristics | Values |
|---|---|
| Fuel line material | Steel, stainless steel, rubber |
| Fuel line length | 21-24 inches |
| Fuel line routing | From tank to pump, from pump to carburetor |
| Fuel pump replacement | Remove and replace fuel lines, catch or plug fuel, remove fuel pump, clean old gasket if needed |
| Gas tank removal | Drain gas, unplug wire from fuel sending unit, disconnect fuel line from sending unit, remove gas cap, remove retaining screws, loosen hose clamps, remove filler neck hose |
| Fuel system installation | Remove tank, remove exhaust system, route new line near front left tire, remove brake line, bend and route new line through grommet into fuel pump |
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What You'll Learn
Removing the gas tank
Next, you will need to remove the filler neck flange by unscrewing the four retaining screws. Loosen the two hose clamps on the filler neck hose and break it loose from the tank. Pull the filler neck hose off and remove the filler neck from the hole in the tail light panel. There will also be a number of sheet metal screws holding the tank to the car, which need to be removed. There may also be a 5/16 bolt that requires a 1/2 inch wrench to loosen.
Once all the screws and bolts are removed, the tank can be lifted out. It is recommended to have the car jacked up and placed on jack stands for this process, with both rear wheels removed. This will provide more room to work and access the necessary parts.
When reinstalling a new tank, the process is essentially reversed. Ensure that all gaskets and seals are correctly placed and torqued to the correct specifications.
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Disconnecting the fuel line
The next step is to locate the fuel line and the fuel pump. Place a small container or pan underneath the fuel pump to catch any gasoline that may drip out when the fuel lines are removed. This is an important safety precaution to avoid any spillage and potential fire hazards. Once the container is in place, you can proceed to disconnect the fuel line.
To disconnect the fuel line, start by loosening the clamp that secures the rubber fuel line to the fuel pump. This can be done by squeezing the clamp's metal prongs together with a pair of pliers. After the clamp is loosened, slide it away from the fuel pump. At this point, you can carefully pull the rubber fuel line off the fuel pump, taking care to catch any residual fuel in the container placed earlier.
In some cases, you may need to rotate the integral nut on the tip of the metal fuel line in a counterclockwise direction with an open-end wrench to fully remove the line from the pump. Additionally, if there are multiple fuel lines, repeat the above steps for each line, ensuring that all connections are securely disconnected.
By following these steps, you can safely and effectively disconnect the fuel line of a 1966 Mustang, preparing for further maintenance or repairs.
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Replacing the fuel pump
If your 1966 Mustang engine isn't getting the fuel it needs, it may be time to replace the fuel pump. You can replace the fuel pump in your 1966 Mustang with a new Carter Fuel Pump, which is one of the highest-quality and most-tested products on the market. Here is a step-by-step guide to help you through the process:
Step 1: Disconnect the Battery
Start by disconnecting the positive battery cable to eliminate any chance of the engine turning over while you work. Place a container or absorbent material under the fuel pump area to catch any spills.
Step 2: Control the Fuel Flow
Clamp the incoming rubber fuel line with locking pliers to stop the fuel flow. If your Mustang still has the original spring-type clamp, remove the clamp on the incoming fuel line with a screwdriver or pliers.
Step 3: Remove the Hose
With the clamp removed, the hose should slip off with a little help from the pliers. Inspect the hose for cracks, wear, or signs of age, and replace it if necessary.
Step 4: Remove the Output Line Fitting
Use a 5/8-inch open-end wrench to hold the Mustang fuel pump output while using a 1/2-inch wrench (preferably a line wrench) to turn the output line fitting counter-clockwise. Inspect the steel line for kinks, wear, or any areas that may be rubbed thin, and replace it if necessary.
Step 5: Remove the Fuel Pump Retaining Bolts
With both fuel lines removed, use a 9/16-inch socket with an extension to remove the two fuel pump retaining bolts. You may need to use a screwdriver to pry the old fuel pump from the engine.
Step 6: Install the New Fuel Pump
Align the new Carter fuel pump and thread in the two retaining bolts by hand. Use a 9/16-inch socket to tighten the bolts, being careful not to over-tighten them.
Step 7: Reinstall the Lines
Reinstall the lines that were removed in steps 1 and 2. Remove the locking pliers that closed off the fuel flow.
Step 8: Test the Installation
Start the engine and check for leaks. If there are no leaks, your new Mustang Carter Fuel Pump installation is complete.
It is important to note that this guide provides general instructions, and you may need to make adjustments based on the specific configuration of your Mustang. Additionally, always exercise caution when working with fuel systems to prevent fires or injuries.
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Installing stainless steel fuel lines
Firstly, it is important to gather the necessary tools and materials, which include a new stainless steel fuel line, a jack, jack stands, and basic hand tools for automotive work. Before beginning any work, ensure the vehicle is parked on a level surface and engage the parking brake for safety.
Next, the fuel tank and exhaust system will need to be removed for access. Place the vehicle on jack stands and remove the rear wheels. Loosen the left rear shock lower end from the differential and remove the exhaust system. At this point, it is a good idea to inspect the fuel tank for any signs of rust or corrosion, and replace it if necessary.
Now, you can begin routing the new fuel line. Place the new line over the differential and route it up near the front left tire. Take note of the brake line and fuel line clips near the drive shaft, and remove any interior components that may obstruct access, such as carpets. Gently bend the new line as needed to match the routing of the old line.
When feeding the new line through, remember to route it through the loop made by the parking brake. Remove the brake line where it bolts up to the lever to make this process easier. Continue routing the line to the fuel pump, making any necessary bends or adjustments.
Finally, secure the new fuel line in place using appropriate clips or fasteners. Reinstall any components that were removed earlier, such as the brake line and interior carpets. With the new stainless steel fuel line installed, you can now fill the fuel tank and check for any leaks. Ensure all connections are secure and tight to prevent fuel leaks and potential safety hazards.
Remember to exercise caution when working with fuel systems, and always work in a well-ventilated area to prevent the buildup of flammable fumes.
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Removing the fuel tank and exhaust system
Before removing the fuel tank, it is important to drain the gas out of it into suitable containers. Unplug the wire from the fuel sending unit and disconnect the fuel line from the sending unit. Next, remove the gas cap and the filler neck. To do this, remove the four retaining screws for the filler neck flange. Then, loosen the two hose clamps on the filler neck hose and break the filler neck hose loose from the tank. Now, remove the filler neck hose from the filler neck and pull the filler neck out through the hole in the tail light panel.
Next, remove the sheet metal screws holding the tank to the car. There could also be one 5/16 bolt, which takes a 1/2 inch wrench. If your Mustang is a GT and has dual exhaust, this bolt won't be there.
If the fuel tank appears to be stuck, you can take a floor jack and a piece of a 2x4 and jack up on the bottom of the tank to break the tank loose.
Now, you can move on to removing the exhaust system. First, use a jack to raise your Mustang and place jack stands under the front frame rails so that you can work underneath the car. Spray penetrating oil on all of the exhaust clamps and remove each of the exhaust studs using a 5/8 inch wrench or socket. If the nuts are rusted, apply more penetrating fluid and wait several hours before trying again.
Remove the Mustang exhaust clamp on the passenger side hanger and lower the muffler to the ground. With the clamps removed, secure the muffler with your hands and work it side to side, rotating it so that it is free from the frame. Make sure you clear the axle, fuel tank and springs. Carefully remove the rest of the exhaust pipes.
Now, you are ready to raise the new exhaust system into place, starting with the front pipes and working to the rear. Place the supplied doughnut adapters on the H-pipe and install the supplied flanges on the left and right exhaust manifolds. Use light gauge wire to tie the back of the Mustang H-pipe to the frame. This will hold it in place while you reinstall the hangers. Tie back the mid-pipes and space them evenly from side to side and along the drive shaft. Place the supplied exhaust clamps at each of the joints and tighten them slightly.
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Frequently asked questions
Removing the gas tank from a 1966 Mustang is a simple process. First, drain the gas from the tank into a suitable container. Next, unplug the wire from the fuel sending unit and disconnect the fuel line from the sending unit. Remove the gas cap and the nut inside the trunk, behind the filler neck. Take out the four retaining screws for the filler neck flange and loosen the two hose clamps on the filler neck hose. Break the filler neck hose loose from the tank and remove the filler neck hose from the filler neck. Pull the filler neck out through the hole in the tail light panel. Finally, remove the sheet metal screws holding the tank to the car.
To remove the fuel pump, first place a small container under the pump to catch any gasoline that may drip out. Remove the line feeding into the pump and out of the pump. Loosen the clamp that secures the rubber fuel line to the fuel pump by squeezing the clamp's metal prongs together with a pair of pliers. Slide the clamp away from the pump and pull the rubber fuel line off.
Jack up the car and remove the rear wheels. Route the new line through the loop that the parking brake makes, removing the brake line where it bolts up to the lever. Gently bend the line to get it through the grommet and into the fuel pump.
