If you drill it, Don't go more than a .187" deep, if i remember right, Could be less. You will drill thru knocking off the inner stud. that the electrical connection is for the armature. That particular pressed in stud kinda looks like this. I thought i had a of actual picture of it.

 

I wouldn't rely on a solder joint without some form of good mechanical retention. I'd give the drill/tap a try if buying a new one is off the table.

 

Also, unfortunately, there is no way to open up this pump to repair it. I've tried, and the "opening up" process is completely destructive to the pump casing.

Below is the link to my thread where I discussed the entire tear down process and pictures of all the components inside, including the head where the studs are cast into the plastic. No "cut-away" shots of the studs in particular, but if you go through the PDF in the thread, you can see the head pics near the end.

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

 

Thanks everyone for all the help. Friday nite I surrendered to the idea that I just messed up and would take the loss and reinstall my old pump. Saturday morn I woke up and went to the auto parts and bought a tap and drill set. Put my broken fuel pump in my vise and filed down the broken stud nice and flat. Used the smallest drill bit I had said a prayer and started drilling slowly. Got to about 1/4 inch and used 6/33 tap and started twisting back and forth. Put 1" in flat screw and screwed in thight . With my hack saw I cut the top off, gently. Installed and attached the lines and it works like a champ. Drove it around and feels good. Checked it again today and all looks good. Thanks again

 

Sometimes a man has got to do...


Remember, to only snug when working without a torque wrench.

 

Sweet!! I'm as it worked for you.

I've broken and break enough crap I my life I've gotten pretty good at " field expedient repairs". I live rural and a parts run is minimum 1.5 hours ( some on this board are much farther ) so sometime you just have to make do until you can get to town, unless the bandaid is good enough then why bother.

I wouldn't sweat your repair in the slightest. It's probably as good as new. I would keep an occasional eye on it though. Dissimilar metals, vibration etc could cause an issue but only time will tell.