when replacing the fuel pump on a 1996 F250 7.3L diesel, when you
take the banjo nut off what is the best way to reinstall it considering
the space you have to work in is restricted by the turbo bracket.

 

WELCOME TO FTE!!!!
Here are some links you SHOULD save!:
1994.5 - 1997 7.3L Power Stroke Diesel - Ford Truck Enthusiasts Forums
http://pages.prodigy.net/stevebaz/_i...az/index3.html
1996 Bronco/F-Series Workshop Manual
97-15A 7.3L DI Turbo Workshop Manual

Now that is out of the way, The Banjo bolt goes back in the same way. Sorry I can't tell you anything else. Blood, Sweat and beers! Someone else may be able to soften the blow with another way. It could be worse! You could have a Cali model.

Again WELCOME TO FTE!!!

 

Thanks copedawg, the links you sent me say to remove the turbo, you do not need to do this, I was looking to see if anybody had a solution.

 

The banjo bolt is not to bad. The part to be careful about is the plunger coming out of the bottom. Be careful not to drop it down in the hole it comes out of. It just snaps into the bottom of the pump.

 

I am not yelling so don't take offense to the CAPS.
THE TURBO DOES NOT HAVE TO COME OFF EVEN FOR THE CALI MODEL'S.
Lots of write ups out here on how to change the pump w/o fuggen with the dreaded turbo.

 

Oh, now I read what you wrote, lol. Those links were just for your future use (the links), ENJOY

 

I can tell you this, dont loose the NEW washers, the front one is the problem (the back goes in the banjo bolt), use some kind of grease to maintain it in place and then reinstall the banjo bolt, the other thing is dont torque the bolts of the fuel pump, till you have reinstalled the banjo bolt by hand, and after that you can torque the banjo bolt. I hope this helps you.

X2 on the welcome a board.

 

One thing that will help is to run the bolt in & out of the pump a few times to make sure the threads are clean . As was said , grease on the second washer .. BTW , the washers should be new ...