Replacing The Fuel Pump In A 2003 F150 Harley Davidson

Replacing the fuel pump on a 2003 F150 Harley Davidson is a complex task that requires some automotive expertise. The fuel pump is located inside the fuel tank, which can be accessed by either dropping the fuel tank or removing the bed of the truck. The process involves disconnecting electrical connectors, removing bolts, and carefully extracting and installing the fuel pump assembly. It is recommended to have an extra pair of hands to simplify the process.

Removing the truck bed

To remove the truck bed from your 2003 F-150 Harley Davidson, you will need to gather some tools and materials. These include a Phillips-head screwdriver, a 1/4-inch ratchet and socket, a 1/2-inch ratchet, extension, and socket, and some friends to help you lift the bed. Here is a step-by-step guide:

Step 1: Prepare the Tailgate and Taillights

Open the tailgate and use your Phillips-head screwdriver to unscrew the taillights from the bedsides. Then, unplug the bulbs from the back of the lens. Push the wiring harness in through the taillight bucket and down to the ground to ensure it doesn't get pulled when you lift the bed.

Step 2: Unbolt the Gas Filler Neck

Open the gas door and use the 1/4-inch ratchet and socket to unbolt the gas filler neck from the bedside. Then, push the gas filler neck into the bed.

Step 3: Unbolt the Bed

Use the 1/2-inch ratchet, extension, and socket to unbolt the bed from the frame. There can be up to eight bolts holding the bed in place, depending on its length, so make sure to remove them all. Push the bolts up through the frame and out of the bed.

Step 4: Lift and Remove the Bed

Get your assistants to help lift the bed. Position them around the bed to distribute the weight evenly. Carefully lift the bed vertically off the frame, being cautious around the wheels. You may need to lift the bed higher to accommodate the wheels. Once clear, lower the bed to the ground.

Now that the bed is removed, you can access the fuel pump assembly. Remember to always exercise caution when working on your vehicle and refer to a qualified mechanic if you are unsure about any steps.

Disconnecting the wiring

Firstly, before you begin the process of disconnecting the wiring, it is important to prepare the vehicle. Park your truck on a level surface and engage the parking brake. Ensure you have the necessary tools, such as a set of wrenches and screwdrivers, and safety equipment, including gloves and eye protection. It is also recommended to have an extra set of hands to assist you in this process.

Now, let's begin with the wiring disconnection:

• Disconnect the negative battery cable: Before proceeding with any electrical work on your vehicle, it is essential to disconnect the battery. Locate the negative battery terminal, which is usually marked with a "-" sign. Use a wrench to loosen the nut securing the cable and carefully detach it from the battery post. Set the cable aside, ensuring it does not touch any metal parts of the vehicle.
• Remove the pickup bed: As the fuel pump is located within the fuel tank, you will need to access it by removing either the fuel tank or the pickup bed. In this case, we will remove the bed. Start by removing the bed liner, if applicable, followed by the six T50 Torx bed bolts. The bolt size may vary depending on the model year, so ensure you have the correct size tool. With the bolts removed, carefully lift and slide the bed back or remove it entirely, providing access to the fuel pump assembly.
• Disconnect wiring for tail and license plate lights: At this point, you will need to disconnect the wiring for the tail and license plate light assemblies. Trace the wires to locate the connectors and carefully disconnect them. Ensure that the wiring harnesses are tucked or positioned in a way that they won't catch on the frame when the bed is moved or removed.
• Disconnect the fuel filler cap and strap: To provide easier access to the fuel pump, you will need to remove the fuel filler cap and the strap that secures the filler neck to the bed. Carefully detach the cap and set it aside, ensuring you don't lose it. Then, remove the mounting hardware and detach the filler neck from the bed.
• Disconnect the electrical connector for the fuel pump: With the bed removed or slid back, you should now have clear access to the fuel pump assembly. Locate the electrical connector that powers the fuel pump. It is usually secured with a clip or clamp. Carefully detach the connector by releasing the clip or unscrewing the clamp, ensuring you don't damage the connector or the wires.
• Label and secure wiring harnesses: Before proceeding further, it is essential to properly manage the wiring harnesses to avoid any accidental damage or disconnection. Label each wiring harness to its corresponding component (e.g., fuel pump, tail lights, license plate lights) to make reassembly easier. Secure the wiring harnesses using zip ties or tape to ensure they don't interfere with the rest of the process.

By following these steps, you will have successfully disconnected the wiring necessary to access and replace the fuel pump on your 2003 F150 Harley Davidson. Remember to work carefully and methodically, and always refer to a qualified mechanic or a repair manual if you have any doubts or concerns during the process.

Removing the fuel tank

To remove the fuel tank from your 2003 F150 Harley Davidson, you have two options: dropping the fuel tank or removing the bed. Both methods will give you access to the fuel pump, which sits at the top of the fuel tank.

If you choose to remove the bed, follow these steps:

• Remove the bed liner and the six T50 Torx bolts securing the bed.
• Disconnect the wiring for the tail and license plate light assemblies. Trace the wires to find the connectors for both.
• Tuck or position the wiring harnesses carefully so they don't catch on the frame when the bed is removed.
• Remove the fuel filler cap and strap that secures the filler neck to the bed.
• Lift the bed and remove, or slide it back to access the fuel pump assembly.

If you choose to drop the fuel tank, you may also want to consider replacing the fuel tank straps, which have been known to corrode. This method will require you to empty and store the gasoline from the tank.

Removing the fuel pump

To remove the fuel pump from a 2003 F150 Harley Davidson, you will first need to decide whether to drop the fuel tank or remove the bed of the truck. Both methods are valid, but removing the bed is generally considered to be more convenient.

If you choose to remove the bed, start by removing the bed liner (if applicable) and then the six T50 Torx bolts that secure the bed. The bolts should have locking tabs, so you won't need to hold the nuts beneath the bed. Next, disconnect the wiring for the tail and license plate light assemblies. Trace the wires to find the connectors for both. Carefully tuck and position the wiring harnesses so they don't catch on the frame when the bed is removed. Remove the fuel filler cap and the strap that secures the filler neck to the bed.

Now you're ready to lift and remove the bed. You can attach tow straps to all four corners and lift it with a chain hoist, or slide the bed back so that you can access the fuel pump assembly.

With the bed removed, disconnect the negative battery cable. The new fuel pump will have an arrow etched into the top cover, so mark this location on the tank with a marker to ensure the new pump is aligned correctly.

Remove the six hex bolts that secure the fuel pump assembly and disconnect the electrical connector. Remove the two fuel lines from the assembly, using a flat-head screwdriver for the retaining clips if necessary.

Carefully extract the old fuel pump assembly from the tank, and remove the old gasket if it's still there.

Reinstalling the fuel pump and testing

Once you have removed the fuel pump, you will need to install the new one and test it.

First, install the new gasket and fuel pump assembly. You can apply a light coating of silicon lubricant to the new gasket to ensure a positive seal. Make sure the arrows on the fuel pump and tank line up, then reinstall the mounting bolts.

Next, connect the fuel lines to the new fuel pump assembly, and then the electrical connector. Reconnect the negative battery cable.

Now, reinstall the bed or tank. When you test the new fuel pump, it is normal for the truck to turn over more than usual during this first start as air is being purged from the fuel line. To avoid this, we recommend cycling the keys to the "run" position several times for 10 seconds at a time before cranking the engine over.

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