I started to do the Hutch mod to my truck today, gathered up the parts and proceeded to drop the tank. Didn't take too long to get the tank free from the truck but came to a screeching halt when I pulled the sending/pickup unit form the tank. Found one of the reasons I can't go below 1/8 of a tank, pickup foot is broke. I ordered one from Diesel Orings, hopefully have it in a few days and can get the truck back together. Tank looked pretty clean inside. I will be doing the harpoon mod also.

 

This is my opportunity to interject something. The foot is a rubber-ish part, and it can disintegrate with time and exposure to what-ever-the-hell additives go in the tank (whether we put it there or the fuel supplier does). When prepping to drop the tank, I can't think of a solid reason for not having a fresh foot on hand. Say the foot looks fine when you drop the tank. How much further will a rubber-ish part last past the 15 years so far?

Slyhuntr - you won't regret putting a fresh foot in... whether it appeared to need it or not. You'll be glad the old one forced your hand, now you won't be driving down the road with doubts dangling from the ceiling over the driver seat.

 

I agree Tugly, I'm new to these trucks and I thought before I started this that the foot was a hard composite material and didn't realize it was rubber or I would have had one in hand.

 

That's where I landed after seeing my son's pickup foot disintegrate a couple years ago in his 2002 year model. I have two in the garage right now, with one begging to begin its life in my Excursion's tank (at least the Ex's fuel pump is begging for it).

 

Will definitely be doing the harpoon mod after taking this pic.

 

Also at the front and rear of the tank there are what appear to be vents or something on the top, the rear was bare but the front has a hose going to something on the frame, hadn't looked at that yet but the hose was pretty rotten. Any ideas what these are? Neither of these are the vent that goes to the fill inlet.

 

They are to be connected together via a metal tube for venting through a vent near the front hose port. You can see what mine looked like in the pictures below when I did the mod. Also, I can now get 30-32 gallons in my 26 gallon short bed tank with the harpoon mod.

 

What type of hose did you use? I need to drop mine also.

 

Chet: I used 3/8" Goodyear 30R9 Fuel Injection Hose (5'-6') My guess is that Raychem also makes a product meeting the 30R9 specification (biodiesel compatible).


https://www.ford-trucks.com/forums/1...-strainer.html

 

I also used 3/8 fuel injector hose since I bought a bunch for the other mods I was doing at the time.

 

Sous: Good job on the Hutch Mod. Really makes a difference at fillup time doesn't it! I have also heard that some guys take a hole saw and then a Dremel to the inside of the stainless steel fill tube so as to be able to use the diesel fuel dispensers at truck stops.

 

I did that as well, it was a pain in the ***, but I am glad I did it when the fill tube was out. The metal for the lip of the tube was much thicker than I had anticipated, but I got it done.

 

Yep, and stainless steel is sure harder than mild steel... Good Job!

 

What size hole saw did you use?

 

One of a Milwaukee Hole Hawg metal set. There are teeth models and grit/teeth models. I will take a look this evening. To keep that non-modified look, you need to go slow and then deburr/polish with a Dremel. Sous, has done it more recently, so he will know.