Replacing The Fuel Pump In Your 1997 Ford F150 Truck

Replacing the fuel pump on a 1997 Ford F150 is a moderately challenging task. The pump is located at the centre top of the fuel tank, and to access it, you must either drop the fuel tank or remove the bed of the truck. The latter option is generally easier, as it avoids the need to empty and store the gasoline from the tank. However, both methods are feasible, and the choice depends on factors such as the condition of the bed bolts. Once access is gained, the pump is not difficult to replace.

How to Replace Fuel Pump on 1997 Ford F150

Disconnecting the fuel tank

• Remove the negative battery terminal using an 11mm wrench. This is an important safety precaution as it disconnects the power source to the fuel pump.
• Loosen the fuel filler neck bracket from the metal line. This will allow you to access the fuel filler neck and vent hose.
• Loosen the vent hose bracket from the metal line and the tank. This will give you more flexibility when removing the vent hose.
• Remove the vent hose from the tank. You may need to use an eight-millimeter socket to undo the hose clamp.
• Disconnect the sensor. This is usually attached to the body or frame of the vehicle.
• Disconnect the fuel pump connector. Use a flat-bladed screwdriver to push in the connector and release the tab.
• Remove the locks from the fuel lines using a flat-bladed screwdriver. Pop them off to access the fuel lines.
• Disconnect the pressure and return lines using a disconnect tool. Be careful when handling these lines as they contain fuel.
• Remove the vent hose from the fuel tank. This hose is typically secured with a spring clamp, which can be removed with needle-nose pliers.

At this point, you have successfully disconnected the fuel tank and are ready to move on to the next step of removing the fuel tank straps and lowering the tank. Remember to work in a well-ventilated area when handling gasoline. It is also recommended to have an assistant to help you hold and lift the fuel tank safely.

Removing the fuel tank

To remove the fuel tank on a 1997 Ford F-150, you will need to first disconnect the fuel tank. This involves removing the negative battery terminal with an 11mm wrench, loosening the fuel filler neck bracket and vent hose bracket from the metal line, and removing the vent hose from the tank. Disconnect the sensor and fuel pump connector, and remove the locks from the fuel lines with a flat-bladed screwdriver. Disconnect the pressure and return lines with a disconnect tool.

Now, you can remove the fuel tank. Have an assistant hold the gas tank while you loosen the 13mm bolt from one side of the strap, letting the strap hang down. Remove the 13mm bolt from the second strap and lower the fuel tank down.

It is important to note that working with gasoline can be dangerous, so ensure you are in a well-ventilated area and take appropriate safety precautions.

Additionally, some owners of the Ford F-150 have opted to remove the bed of the truck instead of dropping the fuel tank to access the fuel pump. This method requires removing the bed liner and disconnecting the wiring for the tail and license plate light assemblies. The bed is secured by six T50 Torx bolts, which need to be removed. This method may be preferred if you want to avoid emptying and storing a full tank of gasoline and find it more convenient to work from the top rather than underneath the truck.

Removing the fuel tank and sending unit

To remove the fuel tank and sending unit of a 1997 Ford F-150, you will need to set aside approximately 2.5 hours. It is important to note that the fuel pump is located at the center top of the fuel tank, so removal of the tank is necessary.

Step 1: Disconnecting the Fuel Tank

• Remove the negative battery terminal with an 11mm wrench.
• Loosen the fuel filler neck bracket and vent hose bracket from the metal line.
• Remove the vent hose from the tank.
• Disconnect the sensor and the fuel pump connector.
• Remove the locks from the fuel lines with a flat-bladed screwdriver.
• Disconnect the pressure and return lines with a disconnect tool.

Step 2: Removing the Fuel Tank

• Have an assistant help hold the gas tank.
• Loosen and remove the bolts from the fuel tank straps.
• Lower the fuel tank down.

Step 3: Removing the Fuel Tank and Sending Unit

• Work in a well-ventilated area.
• Clean dirt and debris from around the sending unit to prevent anything from falling into the tank.
• Remove the bolts from the top of the sending unit.
• Lift the sending unit up and out.

Now that you have removed the sending unit, you can install the new fuel pump.

Step 4: Installing the New Fuel Pump and Sending Unit

• Lower the new sending unit, which includes the fuel pump, into the tank.
• Ensure that the arrow on the sending unit lines up with the dimple on the tank, so that the bolt holes align.
• Tighten the bolts to the sending unit evenly.

Step 5: Installing the Fuel Tank

• Lift the gas tank into place with the help of an assistant.
• Tighten the bolts to the fuel tank straps.

Step 6: Reconnecting the Fuel Tank

• Connect the return lines and clip the safety catch into place.
• Connect the vacuum hose and hose clamp to the fuel tank.
• Connect the electrical sensor.
• Reinstall the filler neck hose and hose clamp to the metal line.
• Reinstall the vent hose and hose clamp to the metal line.
• Reconnect the sensor on the fuel tank.
• Reinstall the vent hose on the fuel tank.
• Tighten down the tank straps.
• Reconnect the negative terminal with an 11mm socket and ratchet.

Finally, cycle the key three times to prime the new fuel pump.

It is important to note that you have the option of either dropping the fuel tank or removing the bed of the truck to access the fuel pump. Both methods are acceptable, but removing the bed may be more convenient as it allows you to work from the top and avoids the need to empty and store a full tank of gasoline. However, corroded bed bolts may prevent you from removing the bed, in which case dropping the fuel tank may be the only option.

Installing the fuel tank and sending unit

To install the fuel tank and sending unit, you will need an assistant to help you lift the gas tank into place.

First, lower the sending unit into the tank. Tighten the 10mm bolts to the sending unit evenly. Then, lift the gas tank into place with the help of an assistant. Tighten the 10mm bolts to the fuel tank strap.

Now, reconnect the fuel tank. Remove the caps from the pressure and return lines. Connect the return lines and clip the safety catch into place. Connect the vacuum hose and hose clamp to the fuel tank. Connect the electrical sensor. Reinstall the filler neck hose and hose clamp to the metal line. Reinstall the vent hose and hose clamp to the metal line. Reconnect the sensor on the fuel tank. Reinstall the vent hose on the fuel tank. Tighten down the tank straps.

Finally, reconnect the negative terminal with an 11mm socket and ratchet. Cycle the key three times to prime the pump.

Reconnecting the fuel tank

Now that you have removed the fuel tank, you can begin the process of reconnecting it.

First, lift the gas tank into place with the help of an assistant. Tighten the 10mm bolts to the fuel tank strap.

Next, reconnect the fuel tank. Remove the caps from the pressure and return lines. Connect the return lines and clip the safety catch into place. Connect the vacuum hose and hose clamp to the fuel tank. Connect the electrical sensor. Reinstall the filler neck hose and hose clamp to the metal line. Reinstall the vent hose and hose clamp to the metal line. Reconnect the sensor on the fuel tank. Reinstall the vent hose on the fuel tank. Tighten down the tank straps. Reconnect the negative terminal with an 11mm socket and ratchet.

Finally, cycle the key three times to prime the pump.

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