Replacing fuel pump
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Cargo Master
Joined: Feb 2010
Posts: 2,526
Likes: 6
From: College Station, TX
Replacing fuel pump
I'm about to finally replace my fuel pump and have a few questions. Is it mandatory to put on new banjo washers? Also is it as straight forward as pulling everything, turning over engine by hand, out with old, in with new, and zip it up? A write up would be nice if anybody has one. Thanks advance
Elder User
Joined: Aug 2009
Posts: 869
Likes: 1
From: Michigan
I did reuse my copper washers. unless theyre really mangled reuse them. check the banjo bolt fit to the new pump before you mount the pump since you can only turn the thing 1/1000th of a turn at a time. also get the pump tappet at top dead center to pull it. be real carefull sometimes the tappet likes to fall out the bottom of the pump and into the engine (not good) it really is out with the old and in with the new. its a good time to fully clean out the filter can (and replace the filter) since you will be removing it. tip it upside down and hose it out with gumout carb n choke cleaner is what i did.
Lead Driver
Joined: Aug 2006
Posts: 5,259
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From: Gambrills
I think the Cali models started in 97. If not and you find you have a Cali model look here: https://www.ford-trucks.com/forums/6...placement.html
Thread Starter
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Cargo Master
Joined: Feb 2010
Posts: 2,526
Likes: 6
From: College Station, TX
I did reuse my copper washers. unless theyre really mangled reuse them. check the banjo bolt fit to the new pump before you mount the pump since you can only turn the thing 1/1000th of a turn at a time. also get the pump tappet at top dead center to pull it. be real carefull sometimes the tappet likes to fall out the bottom of the pump and into the engine (not good) it really is out with the old and in with the new. its a good time to fully clean out the filter can (and replace the filter) since you will be removing it. tip it upside down and hose it out with gumout carb n choke cleaner is what i did.
Thread Starter
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Cargo Master
Joined: Feb 2010
Posts: 2,526
Likes: 6
From: College Station, TX
I think the Cali models started in 97. If not and you find you have a Cali model look here: https://www.ford-trucks.com/forums/6...placement.html
Senior User
Joined: Aug 2010
Posts: 238
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Just search this forum for "sam Miller" and you'll find several posts with his write-up.
I reused my banjo bolt washers (looked like soft steel, not copper) and you get a lot more than 1/1000th of a turn, at a time, on the banjo bolt. I got mine off and on with a stock caraftsman 1.25" combo wrench - no mod required.
Great time to overhaul the fuel bowl if due. At a minimum, change the hoses while its apart. 30R9 (?) rated hose is adequate and the "fuel injection" style clamps are much kinder to the hoses.
I reused my banjo bolt washers (looked like soft steel, not copper) and you get a lot more than 1/1000th of a turn, at a time, on the banjo bolt. I got mine off and on with a stock caraftsman 1.25" combo wrench - no mod required.
Great time to overhaul the fuel bowl if due. At a minimum, change the hoses while its apart. 30R9 (?) rated hose is adequate and the "fuel injection" style clamps are much kinder to the hoses.
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Thread Starter
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Cargo Master
Joined: Feb 2010
Posts: 2,526
Likes: 6
From: College Station, TX
Just search this forum for "sam Miller" and you'll find several posts with his write-up.
I reused my banjo bolt washers (looked like soft steel, not copper) and you get a lot more than 1/1000th of a turn, at a time, on the banjo bolt. I got mine off and on with a stock caraftsman 1.25" combo wrench - no mod required.
Great time to overhaul the fuel bowl if due. At a minimum, change the hoses while its apart. 30R9 (?) rated hose is adequate and the "fuel injection" style clamps are much kinder to the hoses.
I reused my banjo bolt washers (looked like soft steel, not copper) and you get a lot more than 1/1000th of a turn, at a time, on the banjo bolt. I got mine off and on with a stock caraftsman 1.25" combo wrench - no mod required.
Great time to overhaul the fuel bowl if due. At a minimum, change the hoses while its apart. 30R9 (?) rated hose is adequate and the "fuel injection" style clamps are much kinder to the hoses.
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Cargo Master
Joined: Feb 2010
Posts: 2,526
Likes: 6
From: College Station, TX
Thanks guys!!! I got it done earlier today and it runs better than it ever has. I guess the pump had been going for a while. I didn't realize how much pedal id been giving redman lately. After the 5 speed swap and several mods a little fuel is all I needed. Feels like I chipped it today.
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