Replacing A Fuel Pump: 2002 Ford F250 Guide

The fuel pump in a 2002 Ford F250 is located inside the fuel tank. It delivers pressurised gasoline to the engine's fuel injectors. If the fuel pump is faulty, the car may not start or may stall. Other signs of a failing fuel pump include a whirring noise from the fuel tank, or the engine overheating. To replace the fuel pump, the fuel tank must be drained and removed from the vehicle. This can be done by siphoning the gas and using a car jack to elevate the truck, or by removing the truck bed. Once the fuel tank is accessible, the fuel pump can be removed and replaced. This job is best performed by a qualified mechanic or at a dealership's service department.

Disconnect the battery

Disconnecting the battery is the first step when replacing the fuel pump in a 2002 Ford F250 Super Duty. This is a crucial safety precaution to reduce the chance of a fire when working on the fuel system. Before disconnecting the battery, ensure that your F-250 is on a flat and safe surface, and the engine is turned off.

To disconnect the battery, locate the negative terminal, which is usually marked with a "-" sign. Use a wrench or socket to loosen the nut or bolt that secures the battery cable to the terminal. Once it's loose, carefully remove the cable from the terminal. Be cautious not to let the cable touch any metal parts of the car, as it could cause a short circuit.

If your F-250 has a positive terminal disconnect, you will need to repeat the same process for the positive cable. However, always start with the negative terminal first for safety reasons.

After disconnecting the battery, make sure to move the cable away from the battery to avoid any accidental contact. You can use a cable tie or tape to secure it in place.

It is also important to note that modern vehicles have complex electrical systems, and disconnecting the battery may cause certain electronic components to lose their settings. Therefore, it is recommended to make a note of any customized settings before proceeding.

Additionally, some vehicles may have a battery that is challenging to access or remove. In such cases, it is advisable to refer to the owner's manual or seek assistance from a qualified mechanic.

Remember, working with the fuel system can be dangerous, and it is crucial to take all necessary precautions to prevent fires and other hazards.

Remove the fuel tank or truck bed

Removing the fuel tank or truck bed is a necessary step to access the fuel pump in a 2002 Ford F250. Here is a detailed guide on how to do it:

Option 1: Removing the Fuel Tank

This option requires siphoning the gas and using a car jack with stands. You will need to spend time underneath the vehicle, removing all the lines connecting the fuel tank to the truck. Some connections may be rusty and tough to loosen, so be prepared for that. Here are the steps:

Step 1: Remove fuel from the tank. Use a clear hose and an air pump to siphon the gas out of the tank.

Step 2: Elevate the truck. Use a standard jack to raise the truck to a height of at least 18 inches above the ground. Place the jack in the grooves along the frame. If your truck is already lifted, you may not need to do this step.

Step 3: Remove the heat shield. Crawl under the truck and 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 bolts are removed, carefully remove the heat shield.

Step 4: Remove the fuel tank. Place two floor jacks underneath the fuel tank to support it while you remove its bolts. Use an impact wrench to remove the four long bolts from the fuel tank. Lower the straps and twist them off gently to avoid damaging the mounting point. Now, the fuel tank should be supported only by the jack stands. Slowly lower the stands while holding the fuel tank, as the front end is still connected to the fuel fill line. Use a 1/4 inch hex socket to disconnect the fuel fill line. Then, carefully pull the fuel tank out from under the truck.

Option 2: Removing the Truck Bed

If you prefer not to get under the truck and remove the fuel tank, you can opt to remove the truck bed instead. This process requires removing bolts, disconnecting lights and wires, and lifting the bed off the truck. Here are the steps:

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 holding the filler cap in place and let it hang down.

Step 3: Remove the filler neck clamp. Crawl under the truck and loosen the clamp connecting the filler neck to the bed.

Step 4: Disconnect the bed and tail lights. Slide underneath the truck bed and disconnect the wire harness for the bed lighting. Remove the two taillight plugs located at each corner of the bed.

Step 5: Lift the bed off the truck. With the help of two strong people, grab each side of the bed and lift it off the truck. Alternatively, you can use bed hooks, ropes, and a chain hoist to lift the bed. Pull the truck forward and lower the bed onto a soft surface or sawhorses.

Disconnect fuel lines and electrical connections

Disconnecting the fuel lines and electrical connections is a crucial step in replacing the fuel pump of a 2002 Ford F250. Here is a detailed guide on how to do it:

Step 1: Disconnecting the Fuel Lines

• Before beginning, ensure your Ford F250 is parked on a flat and safe surface, and the engine is turned off.
• Siphon the gas from the fuel tank using a clear hose and an air pump.
• Use a car jack to elevate the truck to a height that allows you to comfortably work underneath.
• Locate the heat shield and the bolts holding it in place. Use an impact wrench to remove these bolts.
• Carefully remove the heat shield, being mindful that some connections might be rusty and tough to loosen.
• Once the heat shield is removed, you will expose the fuel tank and its mounting bolts.
• Use the impact wrench to remove the bolts securing the fuel tank.
• With the bolts removed, carefully lower the fuel tank with the help of an assistant.
• Disconnect the fuel fill line at the front end of the fuel tank using a 1/4 inch hex socket.

Step 2: Disconnecting Electrical Connections

• Locate the fuel pump module on top of the fuel tank.
• Disconnect the fuel outlay and relay lines from the module.
• Remove the evaporative hoses by releasing the safety clips that fasten them to the module. You can use a 3/8" Ford Fuel Line Disconnect Tool for this step.
• Ensure you only purchase aluminium disconnect tools, as the plastic ones are not suitable for this task.

At this stage, you have successfully disconnected the fuel lines and electrical connections to the fuel pump. You can now proceed to remove the old fuel pump and install a new one. Remember to reconnect all the lines and electrical connections once you have installed the new fuel pump.

Remove the old fuel pump

To remove the old fuel pump from your 2002 Ford F250, you have two options: removing the fuel tank or removing the bed. Both options require specific tools and a good amount of time and effort, so it's important to be prepared and take the necessary safety precautions.

Option 1: Removing the Fuel Tank

• Siphon the gas from the tank using a clear hose and an air pump.
• Elevate your truck using a car jack and stands. Place the jack in the grooves along the frame of your truck and raise it at least 18 inches above the ground.
• Remove the heat shield. Crawl under the truck and 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 bolts are removed, slowly remove the heat shield.
• Remove the fuel tank. Place two floor jacks underneath the fuel tank to support it while you remove the bolts. Use an impact wrench to remove the four long bolts from the fuel tank. Lower the straps and twist them off gently, then set them aside. Slowly lower the jack stands while holding the fuel tank. Disconnect the fuel fill line using a 1/4 inch hex socket. Carefully pull the fuel tank out from under the truck.

Option 2: Removing the Bed

• Remove the bed. Use an impact wrench to remove the six bed bolts.
• Disconnect the fuel filler cap by removing the three 7mm bolts holding it in place.
• Loosen the clamp that connects the filler neck to the bed of your truck.
• Disconnect the bed and tail lights. Crawl under the truck bed and disconnect the wire harness for the bed lighting. Remove the two taillight plugs located at each corner of the bed.
• Lift the bed off the truck. With the help of two strong people, grab each side of the bed and lift it off the truck. Alternatively, use bed hooks, ropes, and a chain hoist to lift the bed.

Once you've chosen one of the above options, the next steps are the same:

• Locate the fuel pump module. The fuel tank can be found just behind the cab. You will see a round fuel pump module bolted to the top.
• Disconnect the fuel lines and evaporative hoses from the module. Use a 3/8" Ford Fuel Line Disconnect Tool to detach any hard-to-remove fuel lines.
• Clean the top of the module and the tank with a plastic brush to remove dust and dirt.
• Mark a spot on the module and the tank with a Sharpie for proper alignment when installing the new pump.
• Remove the old fuel pump assembly. Use an 8mm wrench to remove the six bolts attaching the gas pump module to the tank. If the module is stuck to the rubber seal, carefully use a flathead screwdriver to pry it up. Lift the assembly out of the tank.

Install the new fuel pump

Now that you've removed the old fuel pump, it's time to install the new one.

First, you'll want to lower the new fuel pump into the fuel tank, ensuring it is aligned with the mark you made earlier with your Sharpie. Next, replace the screws and tighten the new pump. Reconnect the outlay and relay lines, as well as the evaporative hoses.

If your fuel system uses an in-line external filter, it is recommended to replace the filter at this stage. You should also reconnect all the fuel pump supply and return hoses, as well as the EVAP system hoses and electrical connections to the pump.

Once everything is connected, add fuel to the tank and run the engine to test for leaks.

And that's it! You've successfully replaced the fuel pump in your 2002 Ford F250.

Frequently asked questions