Replacing Fuel Pump In 2008 Ford F150: Step-By-Step Guide

Replacing the fuel pump in a Ford F-150 can be done in two ways: by removing the bed or by dropping the tank. The first step is to disconnect the battery to reduce the risk of fire. The fuel pump is located inside the fuel tank, which means there is no easy way to get to it. Removing the bed is a more straightforward process, but it requires the help of two strong people to lift it off the truck. This option is preferable if you don't have the tools, jack stands, or inclination to get under the truck and remove the fuel tank. On the other hand, dropping the tank can be done by one person, but it requires siphoning the gas and using a car jack and stands. This option may be more challenging due to rusty connections, but it could be the only option if the fuel pump is located under the cab.

Removing the fuel tank

The fuel pump on a Ford F-150 is located inside the fuel tank, so to access it, you will need to remove the truck bed or the fuel tank. Here is a step-by-step guide on how to remove the fuel tank:

Step 1: Safety first

Always ensure your Ford F-150 is on a flat and safe surface with the engine off before performing any DIY procedures. It is also important to drain the gas tank before making any repairs.

Step 2: Remove fuel from the tank

Before removing the fuel tank, it needs to be empty or close to empty. Use a clear hose and an air pump to siphon the gas out.

Step 3: Elevate your truck

Use a standard jack to raise your vehicle. Place it in the grooves along the frame of your truck and elevate it to a height of at least 18 inches above the ground. This will give you enough space to work underneath.

Step 4: Remove the heat shield

Crawl under the truck and locate the heat shield protecting the fuel pump. 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 first. Once the bolts are removed, slowly remove the heat shield and set it aside.

Step 5: Support the fuel tank

Place two floor jacks underneath the fuel tank to support it while you remove its bolts. Make sure the jacks are raised just enough to support the tank. You can also insert soft padding between the jack stand and the tank to prevent any damage.

Step 6: Remove the fuel tank bolts

Use an impact wrench to remove the long bolts from the fuel tank. Once the straps are loosened, carefully lower and twist them off. Do not force them, as you may damage the mounting point. Set the straps and bolts aside.

Step 7: Lower the fuel tank

Ask an assistant to slowly lower the jack stands while you support the fuel tank. The front end of the tank is connected to the fuel fill line, so you will need to disconnect this using a 1/4 inch hex socket. Once the fuel fill line is disconnected, your assistant can lower the jack stands, and you can pull the fuel tank out from under the truck.

Now that the fuel tank has been successfully removed, you can proceed to locate and clean the fuel pump module.

Disconnecting the battery

Before beginning any work on your Ford F-150, it is important to disconnect the battery to reduce the chance of a fire. This is a simple process but must be done with care.

First, ensure your F-150 is on a flat and safe surface with the engine off. Next, locate the battery under the hood of the car. You will see that the battery has two cables attached to it, a positive and a negative. Identify the ground battery cable, this is usually attached to the negative terminal and is marked with a '-' symbol. You will need a wrench to loosen the nut holding the cable in place. Once the nut is loosened, you can carefully remove the cable from the battery terminal. Be sure not to let the cable touch any metal parts of the car, as this could cause a short circuit.

Now that the battery is disconnected, you can proceed with the rest of the fuel pump replacement process, which involves removing the fuel tank or the truck bed to access the pump.

Once you have successfully replaced the fuel pump, you can reconnect the battery. Simply attach the ground battery cable back to the negative terminal and tighten the nut with your wrench. Ensure the cable is secure and cannot move around. Now your Ford F-150 is ready to start and you can turn the ignition key to the 'On' position.

Accessing the fuel pump

The fuel pump on a Ford F-150 is located inside the fuel tank, which makes it difficult to access. There are two common methods to access the fuel pump for replacement: removing the truck bed or removing the fuel tank.

Removing the Truck Bed

This method is generally preferred if the fuel tank is nearly full. The steps are as follows:

• Remove the bolts keeping the bed in place.
• Disconnect the bed and tailgate lighting.
• Remove the wire harnesses for the bed lighting and tail light plugs.
• Disconnect the fuel filler cap and fuel filler neck clamp.
• Lift the bed off the truck, requiring two strong people or the use of bed hooks, ropes, and a chain hoist.

Removing the Fuel Tank

This method is generally preferred if the fuel tank is empty or near empty. The steps are as follows:

• Siphon the gas out of the tank using a clear hose and air pump.
• Elevate the truck using a jack to safely work beneath it.
• Remove the heat shield using an impact wrench.
• Support the fuel tank with two floor jacks and remove the bolts.
• Lower the fuel tank and disconnect the fuel lines, vapor lines, and fuel pump electrical connector.

Locating and Cleaning the Fuel Pump Module

Once you have accessed the fuel tank, the next step is to locate and clean the fuel pump module. This process is the same regardless of whether you removed the truck bed or the fuel tank.

• Identify the round fuel pump module bolted onto the top of the fuel tank.
• Disconnect the fuel outlay and relay lines, as well as the evaporative hoses, from the module.
• Clean off dust and dirt from the top of the module using a plastic brush to prevent debris from falling into the tank.

Replacing the fuel pump

Step 1: Prepare your Ford F-150

Before you begin, ensure your Ford F-150 is on a flat and safe surface with the engine off. It is also recommended to drain the gas tank. If your gas tank is nearly full, it may be best to remove the bed instead of dropping the tank.

Step 2: Jack up your vehicle

Use a standard 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.

Step 3: Remove the heat shield

Crawl under the truck and locate the heat shield, which is protecting the fuel pump. Using an impact wrench, remove the bolts holding the heat shield in place. As you remove the bolts, place your knee against the heat shield to prevent it from falling on you. Once the bolts are removed, carefully wiggle the heat shield free and set it aside.

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 long bolts from the fuel tank. Once the straps are loosened, lower and twist them off gently. Set the straps and bolts aside, and carefully lower the fuel tank with the help of an assistant.

Step 5: Locate and clean the fuel pump module

The fuel pump module is bolted onto the top of the fuel tank. Disconnect the fuel outlay and relay lines, as well as the evaporative hoses, from the module. Use a plastic brush to clean off any dust or dirt from the module and the tank.

Step 6: Remove the old fuel pump assembly

Make a mark on the module and the tank to ensure proper alignment when installing the new pump. Remove the bolts attaching the gas pump module to the tank and carefully lift it out. If the module is stuck, use a flathead screwdriver to pry it up gently.

Step 7: Install the new fuel pump assembly

Place the new fuel pump assembly into the fuel tank, aligning it with the mark you made. Secure the assembly with the screws and reconnect the outlay, relay lines, and evaporative hoses.

Step 8: Reassemble your truck

Reinstall the fuel tank and reconnect all straps, bolts, and the fuel fill line. If you removed the bed, you will also need to reinstall it and reconnect the lights, gas fuel filler cap, and neck clamp.

Step 9: Final checks

Reconnect the ground battery cable and the electrical connector located on the frame rail. Attach the splash shield to the frame rail using a ratchet and socket. Turn the ignition key to the "On" position for three seconds, then turn it off. Repeat this cycle three times to ensure the fuel system has built up enough pressure. Finally, start the engine and check for any fuel leaks.

Note: It is recommended to have your vehicle serviced by a professional mechanic or a certified repair shop.

Reattaching the fuel tank

To reattach the fuel tank of your 2008 Ford F-150, follow these steps:

Firstly, ensure that you have already completed the fuel pump replacement. Then, lift the fuel tank just enough to attach the fuel lines and vapour lines, and plug the pump module electrical connector.

Next, raise the fuel tank to set it in its mounting place and secure the tank straps using a ratchet, ratchet extension, and socket.

Now, install the fuel tank shield using the ratchet, ratchet extension, and socket if you had to remove it.

Connect the ground battery cable to the battery using a wrench.

Plug the electrical connector located on the frame rail underneath the driver's side door.

Finally, attach the splash shield to the frame rail using the ratchet and socket.

Turn the ignition key to the "On" position for three seconds to let the fuel system build pressure. Then, turn the key to the "Off" position. Repeat this cycle three times to ensure the system has enough pressure.

Start the engine and check for fuel leaks. If there are no leaks, your fuel tank reattachment is complete.

Note: This procedure assumes that you have already drained the fuel tank, jacked up the truck, and removed the necessary components to access the fuel pump. Always refer to a qualified mechanic or a professional repair manual for specific instructions and safety precautions before attempting any repairs or maintenance on your vehicle.

Frequently asked questions