1987 - 1996 F150 & Larger F-Series Trucks1987 - 1996 Ford F-150, F-250, F-350 and larger pickups - including the 1997 heavy-duty F250/F350+ trucks
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First, remove your old fuel pump module from the hanger. Cut the red and black wires close to your old fuel pump module to make sure you have enough wire to splice in your new Walbro module. I didn't have to extend the fuel level wire, I simply unwrapped it from the hanger tubes. Walbro includes instructions on how to remove the hanger from the module. Then, cut two lengths of 3/8 tube. One will be 5 1/8", the other will be 5 3/8". The shorter one will be used for the feed. Then, cut one length of your 5/16 tube at 5 1/8". Using your unions, connect your extension tubes to your stock fuel pump hanger:
After your extension tubes are attached to your stock hanger, you can install the hanger into your new fuel pump module:
Walbro included crimp on butt connectors for the positive and negative fuel pump wires, but I chose to solder and heat shrink instead.
That's pretty much all of the "hard stuff", which is actually pretty simple. Spectra includes longer bolts and spacers for your fuel tank straps, from here it's just a basic tank installation.
After installing everything, I realized my fuel gauge was pegged at full, with an empty tank. After some research and help from a friend, I realized that the fuel level sensor grounds via a bracket that's welded onto the hanger assembly. This bracket is moved up once you add your extension tubes in, and by doing so, ground for the fuel level sensor is lost. I added a ground wire to the assembly, and my fuel gauge works just fine now. Pics:
Stock grounding via bracket and screw:
Lower ground wire attachment at the fuel level sensor bracket:
Upper ground wire attachment at the hanger tube bracket:
Thanks for the write-up! A lot of people ask about this mod and there aren't many comprehensive write-ups on how to do it.
How much taller is the F26D tank than the stock? I have a DMI hitch which extends below the fuel tank and I'm wondering if I have room to do this mod.
It hangs about 6" lower than the stock tank. If you need a particular measurement from somewhere on the frame, let me know!
Originally Posted by Fastback460
Thanks man...My rear tank leaks so I will probably try this, will let me make less trips to the gas station. That 460 is always thirsty
Back in October '12, the wife and I towed my buddy's Scout out to the Saginaw area of MI. Got just about 10-11 MPG. With a 19 gallon single tank, I was stopping every 150 miles to fuel up! Great for her bladder, horrible for time.
Originally Posted by Jarryd
I'd like this mod but damn I'd hate filling that thing up.
Yep, the first fill up is gonna hurt for sure! But, after the initial fill up, I'll just keep throwing 40 bucks a week in it like I did before.
Did you modify the arm for the float at all? Seems like it would keep the gauge showing "Full" for the first quarter/half of the tank without some modification.
I didn't modify it. I figure once it starts moving off the full mark, I'll know I have about 18 gallons or so left.
Originally Posted by 83capril
Going to subscribe to this. Great write up.
Thanks! I'll be editing my first post with another photo tonight. One thing I forgot about, is that the fuel level sensor grounds to the hanger bracket. Extending the lines removes that ground, so I'll need to add a wire in, so that the fuel level sensor works.
I'm was really considering doing this, it's a great idea and this write up makes it look pretty simple.
But then I looked under my truck today, and realized that my exhaust is only about 3 inches from the bottom of the tank .
I don't really want to cut up the exhaust and lower it, so I may be going with the regular 19 gallon after all.
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