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Old 06-26-2009, 01:29 PM
cookkd cookkd is offline
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Trolling for opinions......

This is not Aero specific, but it would apply when replacing a fuel pump on a 'Star.

My fuel sending unit on my 94 Jeep went out and it is part of the fuel pump assembly. I am going to replace it, and in order to do so I have to empty the tank. Can I just unhook the pressure hose at the fuel rail and put the key in run and dump the fuel into a gas can? Or is it possible to overheat the pump doing that.......... or any other suggestions........
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Old 06-26-2009, 01:39 PM
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96_4wdr 96_4wdr is offline
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fuel pumps don't get sufficient cooling when the tank is below 1/4 full or so, depends on design and placement

check your tank first for easy removal of the fuel pump/sending unit assembly. pump the gas out of the same hole.

or use a gas rated drill pump with fittings on the line at the input to the fuel filter or wherever you can tap into the fuel line. pump away into your can.
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Old 06-26-2009, 02:10 PM
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I would think you risk damaging the pump.
Why not use an Oklahoma credit card (siphon hose) to drain it? You could get it low enough to lower the tank on a floor jack.
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Old 06-26-2009, 05:06 PM
xlt4wd90 xlt4wd90 is offline
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The fuel pump will only run for 2 seconds with each key-on if the engine is not also running. You will have to connect a wire directly from the battery to the pump or relay in order to keep it running.

When in operation, the fuel pump runs continuously, so as long as there is fuel in the tank, it is being cooled. If you wanted to do this, you need to make sure to turn it off as soon as its starts running dry to prevent the pump from burning out. For safety's sake, make the disconnection as far away from the fuel area as possible. Electromagnetic devices will produce their biggest spark when their supply current is being disconnected. Pumping fuel in the open will generate fumes, and even a little spark can set them off.

Depending on the configuration of the tank, or where the pump/sender mounting is located, you may not have to drain all the fuel out to get at them. I was able to service the mounting plate for the pump/sender on my Aerostar tank with the tank about half empty. I tilted the outside half of it down enough to get at the plate after loosening the mounting straps.
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Old 06-27-2009, 05:13 PM
cookkd cookkd is offline
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It really doesn't matter if the pump goes, the sending unit and pump are one assembly. Replace one you replace both. I guess just for safety sake I'll get a hand pump to get most of the fuel out and then, as xlt4wd90 suggested, see if I can get at the mounting without having to take the tank completely off.

Thanks guys.
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