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Fuel Pump Replacement - 2002

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Old 01-21-2011, 10:44 PM
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tpdaniels tpdaniels is offline
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Fuel Pump Replacement - 2002

I normally stay over on the older classic site, I have a 72 F250 Highboy in the middle of a total restoration, but wanted to share my fuel pump repair on my 2002 with anyone who is not sure about doing it themselves. My truck is a 2002 XLT Extended Cab 4WD, 189,000 miles.

I have been having intermittent fuel pump problems, it started about six weeks ago by about one out of every 20 times starting the truck the fuel pump would not prime, thus engine would not run, wait five minutes and it magically fixes itself. It has progressively gotten worse to the point last Saturday it refused to restart at the local BBQ drive thru and AAA came to my rescue. The point of this is that after a week of reading post here and other sites on how to change the pump, I was convinced there was no easy way to do it. I decided this morning I was going to fix it one way or the other, here is what I did, also I did all this by myself with no help. After much research, doing this from the top was by far the best option, I first checked to make sure there was no pressure on the fuel rail, I then loweried the spare tire and slid it to one side out of the way, next I removed the rear bumper, 4 Nuts, them removed the six bed bolts(#50 Torx), removed the three screws holding the gas tube to the bed . I then slid the bed back about three inches, I then used my two ton car jack and a 2X4 about 34 inches long, went straight up beside the driveshaft and lifted the front of the bed about fifteen inches, right in front of the rear wheels on both sides I put a eight inch thick block between the frame and bed to support it, then relived the pressure on the jack and was ready to remove the pump. I went in between the frame and bed on the driver’s side, just squeezed up in there and the pump was right in front of me and very easy to remove. It does take a special tool to remove the fuel lines, its two different sizes, I had one that I bought years ago to change fuel filters.

I disassembled the unit, I only replaced the pump itself not the whole unit, I took the old pump with me to NAPA and bought a Bosch replacement pump and tank filter, Total of $91.00 for everything. I just reversed the order and had the truck finished in no time. The total working time on this was less two hours.

The reason for this long post is don’t let the repair shops rip you off, if you have any mechanical ability, a few tools and a place to do it, this is one job you can do yourself, if you have help it’s a no-brainer, you can easily lift the bed off and move it back a few feet out of the way and the pump is real easy to access.

I must add that by no means is this “THE” way to do this, but it is a way. If you do this, common sense is the best tool you have, make safety your number one priority, disconnect your battery and NO SMOKING.
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Old 01-22-2011, 04:48 AM
Davisio Davisio is offline
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I had read that removing the bed was the way to go. Was fearful of moving it out of the way and not hitting anything with it. Never thought about just lifting the bed enough to get access. Coolness! When it comes time, I will, at least, give it a shot. Thanks!
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