Hey y’all, dropping the tank today to do the hutch mod so I can fit those extra gallons in the tank with ease. While I’m in there I’m going to replace the fuel pickup foot and the two screens inside the sending unit. I am NOT harpooning the tank, just cutting the hose for the hutch mod.

my only question is I’m seeing people who have done this and then had fuel related issues like no starts/ sputters. I read that you should empty the fuel bowl, and re prime the system (same process as a fuel filter replacement) after completing the hutch mod. Some videos I’ve seen they put it all back together and go. what are the correct steps to doing this?

thanks as always..

 

It's not clear to me what you're doing. The harpoon mod is cutting the tube/pipes that lead into the tank from the filler and vent tube. "Cutting the hose for the hutch mod" is not part of the hutch mod in this context. Also, if you are not removing the mixing valve and moving the return farther away from the pickup, then you aren't doing the hutch mod in the original spirit of the mod either. I think you're just replacing the fuel pickup foot and doing the harpoon mod.

After dropping the tank, you should definitely key it on, let the pump run until it gives up, several times. If you listen closely you can hear the bubbles circulating out of the system. Just do it until you don't hear it, then do it a few times more until it's cleared up. A ton of air going through the fuel side of the injectors is not nice to the very sensitive nozzles as the fuel is the lubricant for the moving parts.

 

Sounds like you got them mixed up. But priming these trucks is easy. Just cycle the key a few times and let fuel pump do its thing.

 

I must have made a mistake, I apologize. Yes, I am cutting the hoses inside the tank back to make it easier to fill up.

 

yea mixed them up, no biggie. I figured I’d prime the fuel system afterwards I was just so confused. Wanted to mitigate as much bs as I could with this job

 

As others have metioned prime the system a few times. When I did mine I cycled the key 3 times (turn the key to ON, wait for the fuel pump to stop making noise, turn the key to OFF). It cranked a little longer than normal but not much.

The harpoon mod was an easy one to do while the tank was out and open for the Hutch mod. I used a $3 PVC cutter from Harbor Freight and it took about 2 minutes (and no mess). Got a few extra gallons capacity which was great for long trips and off-roading. I never had an issue with overflow, spillage, or fuel system issues the 10+ years I had the truck after the mod.

 

hell yea man, all good just got it sealed up and filled up.



Fitting all 29gal wonderfully, the foot was broken off and pieces of plastic from it as well. Didn’t do the other part of this mod because she rolls great stock for me. thank you for the feedback!

 

Did you get that crap out of the bottom or leave it there?

 

Doing the harpoon mod and cutting the tubes off in inside is well worth it. Might used to spit back out the filler neck before when it got full and made a mess. Plus the extra gallons you can get in it. I've gotten 31 gallons in mine before since I have done. That's with the small tank. Never spits back out either.

 

yea I got it out, it was all sediment from the broken pickup foot. Was a major pain but well worth it

 

Just a bit of additional info for you. The "OEM-rated" 28/29 gallon fuel tank will hold a good bit MORE than 29 gallons - as much as 34-35 gallons!

I have the same tank in my truck. When I did the H&H mod some 13-15 years ago, I made sure that the fill and vent hoses (from the filler nozzle on the sidewall to the tank) were both in excellent condition and well-tightened on both ends. Since doing that, I fill up to the point of being able to see the liquid fuel level in the filler neck on every tank fill. I have, on multiple occasions, pulled up to the pump at the station (different stations, even) and have put in over 34 gallons of fuel without overflowing the tank. I've never seen any evidence of fuel leakage from any of the tank connections or any evidence of overflow in all of my fill-ups in the >200K miles I've put on the truck since that time.

Yes, my fill-up technique goes past the pump "click off" fill, and I tweak the nozzle to get that extra 0.9-1.2 gallons so I can see the fuel level, and it takes an extra 2 minutes. My rationale is so that I can KNOW exactly where the level is for precise fuel economy tracking/comparison between stations, driving conditions, fuel brand, etc.

I'm not saying that everyone needs to do what I do... just saying that three is more mileage to gain between fill-ups if that is something you want to achieve.

YMMV

 

I do the same. I hate the small tanks on these thing traveling with a camper. Got to stop every 4-5 hrs.

 

This is the best reason to delete all of that stuff from the tank. These parts will fail and you have to go inside the tank to fix them. ‘Hutch’ and many others make this more complicated and expensive than it needs to be.

https://www.ford-trucks.com/forums/1...poon-mods.html

 

that’s a great write up, I wish I would have read more before doing it. I just wanted those extra gallons in the tank because only fitting 24ish gallons at a Time goes quick. The few extra do make a difference. Thank you !

 

I did the H&H mod in 2009 and re-installed the original pickup foot. Fast forward to 2019 when I installed the Racor PS120 I dropped the tank again just to check and sure enough the foot was in pieces in the bottom. I bought a new foot and installed it. Now I am wondering how long the new one might hold up and if I should drop the tank again and do it Jason's way.