96 F250 7.5l dual tanks. When driving along with switch in front, engine chugs and stutters. Switch to rear, smooths out. Every time. I think it's a bad front tank pump, right? I see a lot of folks talk about eliminating a tank. Is that because the system is difficult to fix, or because people don't want to spend the $$ for new pump? I want to fix mine and replace the pump (if that's what it is) but not turn it into a nightmare domino effect of changing part after part. Been there, done that.

 

It's probably the front in-tank pump as you say. It's pretty common with these trucks. People eliminate a tank because of the effort and expense involved in replacing the pump. They also think that with one tank instead of two, it's cheaper to fill it up.

 

I had the same symptoms only with my rear tank being the problem... I changed the pump and its all better.... I'm not sure why people eliminate the tanks..the pump is around $130 but I for one like to have all the gas available especially with the 7.5l... The newer trucks like your 96 don't have the back fill or tank switch problems like the earlier ones and thats another reason people took a tank out...

 

I don't see why people eliminate one of the tanks... It's like $100-$125 for a complete pump, sending unit, and screen. Yes the repair is a pain. I prefer to pull the bed and have everything held in place as I take the old pump out and drop the new one in. Some people like to drop the tank for this proceedure but that's kinda a pain if there is still fuel in it plus all the road dirt on the underbody falling on you and in your face the whole time... Anyway, pulling the bed or dropping the tank is the worst of the problems but nothing that a couple hrs of wrench time can't fix.

Also I would certainly not eliminate one of the tanks if you have the 460! That gas monster needs all the fuel capacity it can get!

 

So it pretty much boils down to laziness! It's a crew cab short bed, so there's only 6 bolts, 2 elec connectors, and 2 filler hoses. I've had bed off before to replace gasket on the same tank before i realized pump was going out. Was a piece of cake. I was hoping it wasn't a case of replacing the pump then finding out it wasn't the problem.

 

nope just yank that bed back off, take the lock ring off and pull the entire unit out. If your gas guage works and your screen is still intact you can just buy the pump... But it seems like buying the entire 3 piece unit is only $20-30 more...

Should cost you a $100-$130 and a case of beer if you need help lifting the bed from friends.