Fourth fuel pump in 2 years, ford pump went, replaced with 2 aftermarket ones, after they went I got a new ford fuel pump, it lasted a month, I barley made it home this morning.

I dropped the fuel tank, it was clean, all screens were clean. Am going to check voltage to pump and see if its getting some strange voltage, anyone know what the current draw should be? I'm at a loss for ideas. when I change fuel filter there's some crap in the bowl but not enough to alarm me.

here is a previous thread that had a lot of good ideas before I realized it was my fuel pump. https://www.ford-trucks.com/forums/1...up-smokes.html

 

all the searching I have done I come up empty, someone talks about a fuel pump regulator near fuel bowl, is that only on earlier models? or a bad relay, but I don't see how that will cause this problem unless I have corroded connection or wires causing excessive resistance... but I doubt it.
It's like the pump looses its ability to pump enough fuel/ pressure, it just runs and runs, not sure if the impeller is bad or its losing power. I might cut one open tomorrow and look inside to see if I can see anything.

And possibly putting in an inline filter before pump, I think i might have to eat this pump cost, nobody wants to warranty them.

 

replaced the return bypass, figured it might have been causing the problem, seemed better. Pump was getting 13.64 volts, that seem ok, close to battery voltage

 

I would do the hutch mod while everything is apart, have you looked at the screens in the mixing chamber? My guess is it could be getting clogged.

 

How do you know it's the fuel pump going bad? Something seems very strange to me...aftermarket parts are always an easy scapegoat, but having two OEM pumps go bad just seems strange to me.

 

I dont have a mixing chamber, thats where my questions came from, will that sending unit benifit from hutch mod, where can i order a kit?

 

Do the pumps still run but not pump? Or do they lock up and not run when they go out?

Whats your fuel pressure at?

 

Do you have a D&W Diesel franchise near you? Either way give them a call. They stock the Delphi replacement. A co-worker whom is off today so I cant ask specifics had the same problem with an 03 or 04 diesel. D&W helped him solve the problem. He hasnt had the problem in a year or so now. If I remember he did the same drill 2-3 pumps, 2 were aftermarket (offshore junk) and one was the Delphi which was cheaper than the Ford unit through D&W. We work for Delphi so we know the pumps. They meet of exceed the FOMOCO and in some cases are the FOMOCO. He also had a ton of water and other contaminants in the bottom of his tank which is what started his problem.

 

keep running, but sound terrible, cannot maintain pressure, will get it to 70 but if you get on it it will drop to 20-30

 

What does the inside of your tank look like? The steel tanks on the cab & chasis models had problems with the tank liner coming off and it would block the fuel pick up and cause a restriction.

If you can make the problem happen on a consistent basis, rig up a temporary fuel tank in the bed of the truck and pull the fuel from there, even if it's only a small container. That should tell you if it's the pump or the tank assuming you can make the problem happen in a known amount of time or circumstance.

 

pulled my tank again and found some problems, rust on the backside of tank, not easy to see, Some floating in fuel. I orderd a new plastic tank. should be in this week. I will let you know how I like it since it is 1/2 the price of a ford oem one.

There is some rust on the fuel float rod, any thing I should do to clean, protect it? Im goign to do the hutch mod befor it goes back together along with a inline filter between tank and pump, new pump and new fuel filter. I better have no more fuel issues after all of this!!

 

Moved to the 1999 - 2003 7.3L Powerstroke Diesel forum.

 

If you don't have screens or any type of filter before the pump then the screen inside the pumps could be getting clogged up and restricting flow.

 

might want to blow the lines out when you replace the tank, there may be some crud hiding in there......

also it looks from the original picture that your fuel return is pointing straight at or near your pickup foot. You might want to put a bend in it and leinghten it to get aerated/heated fuel away from the pump intake. aerated fuel is not a good lubricant for injectors or pumps.

 

Thats your problem right there. Somewhere along the way you have a restriction. I have a fuel pressure guage and the most deviation I have ever seen is 5 psi. I'd run a temporary fuel line to bypass the stock one.