Fuel Pump problems
Senior User
Joined: Mar 2002
Posts: 235
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From: Torrance, CA
also - this might be a stupid question but if my gas tank is full - is it impossible to replace the fuel pump? I was looking at chiltons and haynes and it sounded like I had to remove the fuel tank to replace the fuel pump. And 30 gallons seems a tad bit heavy to lift up 
. Hope someone can help me... 
. Hope someone can help me...
Senior User
Joined: Jun 2004
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You have to siphon out the gas in the tank to get to the fuel pump and sender as it is inside the gas tank... you could leave the gas in if you have a death wish I suppose but for safety's sake, siphon the gas! You will need to drop the tank to access the fuel pump. I have even seen people cut an access hole on the floor of the rear cargo area to avoid dropping the tank. Irregardless, siphon the gas out! When I changed mine out the hardest part was dropping the tank. I got an A/C Delco pump for $130.00 you can get that at any parts store. The sender is a dealer item and it cost $32.00... you will crimp the new connection to the new pump unless you are prepared to switch out wires at the connector... you will see what I mean when you have it out... another thing, did I mention to SIPHON THE GAS OUT BEFORE YOU BEGIN!
Last edited by redrumybronco; Jul 5, 2004 at 01:50 AM.
Senior User
Joined: Mar 2002
Posts: 235
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From: Torrance, CA
red -
yea... i'll definately siphon the gas.
cause i was going to say.... 30 gallons is pretty heavy... I hope kragen or pep boys is open tomorrow.
so red - i need to get the a/c delco pump and the sender? you have any tips on dropping the tank? any pics or installs somewhere online?
btw my truck is a '94 XLT 5.8
thx
yea... i'll definately siphon the gas.
cause i was going to say.... 30 gallons is pretty heavy... I hope kragen or pep boys is open tomorrow.
so red - i need to get the a/c delco pump and the sender? you have any tips on dropping the tank? any pics or installs somewhere online?
btw my truck is a '94 XLT 5.8
thx
Senior User
Joined: Mar 2002
Posts: 235
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From: Torrance, CA
one more question red - do these things suddenly die? I read somewhere that it could be the EEC relay... looking all over for this thing... where can I find it.
Also before I go out and buy a fuel pump and siphon the fuel - I also read that I should test to see if the fuel pump is getting fuel. Can I access this harness or switch without removing the fuel tank?
thx
Also before I go out and buy a fuel pump and siphon the fuel - I also read that I should test to see if the fuel pump is getting fuel. Can I access this harness or switch without removing the fuel tank?
thx
New User
Joined: Jul 2004
Posts: 3
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fuel pump shut off
on fuel shut off well what it is doing it turns over but wont start acts like its out of gas,i have replace just about everything i can thing of except the pump but you can here it kick in when you turn the key on.was running fine but would bog down like it wasnt getting enough gas or something,and now wont start at all but a pub,any help i can get is helpful.
Senior User
Joined: Jun 2004
Posts: 207
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tips on dropping the tank:
1. power wash underneath vehicle, especially around the tank and skid plate
2. use eye protection, gloves and half mask, even though you powerwashed, there are still things that will go into your eyes and mouth that you don't want
3. use penetrating oil on all bolts and nuts
4. don't use a creeper, instead use a large cardboard to move about freely
5. use wheel ramps instead of jack stands if you have them, the higher the vehicle the easier it will be
6. once you have the tank out, wash and dry the top before opening the pump lid... you dont want anydirt falling in the tank. also put cover on gas inlet tube while you make new connections.
7. NO SMOKING!
If its not your relay, then its the pump... I have heard that fuel pumps suddenly die for no explicable reason other than normal wear and tear or life expectancy for a particular model... I think there are other brands besides a-c delco, a mechanic friend of mine told me to get that one in particular, I didn't ask him why and figured that he knows what he is talking about. The sender is Motorcraft available at the dealer only.
you can access the harness before you drop the tank and you should disconnect it beforehand. I don't have any pics as I didn't have a digital camera at the time. sorry.
1. power wash underneath vehicle, especially around the tank and skid plate
2. use eye protection, gloves and half mask, even though you powerwashed, there are still things that will go into your eyes and mouth that you don't want
3. use penetrating oil on all bolts and nuts
4. don't use a creeper, instead use a large cardboard to move about freely
5. use wheel ramps instead of jack stands if you have them, the higher the vehicle the easier it will be
6. once you have the tank out, wash and dry the top before opening the pump lid... you dont want anydirt falling in the tank. also put cover on gas inlet tube while you make new connections.
7. NO SMOKING!
If its not your relay, then its the pump... I have heard that fuel pumps suddenly die for no explicable reason other than normal wear and tear or life expectancy for a particular model... I think there are other brands besides a-c delco, a mechanic friend of mine told me to get that one in particular, I didn't ask him why and figured that he knows what he is talking about. The sender is Motorcraft available at the dealer only.
you can access the harness before you drop the tank and you should disconnect it beforehand. I don't have any pics as I didn't have a digital camera at the time. sorry.
Last edited by redrumybronco; Jul 5, 2004 at 06:01 PM.
Senior User
Joined: Mar 2002
Posts: 235
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From: Torrance, CA
red-
Thanks for the info about the install,
I want to be 100% sure that the pump is dead... I took some pics. And asked about it on another thread
http://www.fordtruckenthusiasts.com/...d.php?t=257429
If I am getting that kind of voltage does that mean my electrical stuff (relays, EEC stuff etc) is ok, and my fuel pump most likely died?
Thanks for the info about the install,
I want to be 100% sure that the pump is dead... I took some pics. And asked about it on another thread
http://www.fordtruckenthusiasts.com/...d.php?t=257429
If I am getting that kind of voltage does that mean my electrical stuff (relays, EEC stuff etc) is ok, and my fuel pump most likely died?
Senior User
Joined: Mar 2002
Posts: 235
Likes: 0
From: Torrance, CA
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Senior User
Joined: Jun 2004
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You don't have to change out the sender if it is working properly, mine gave out way before the fuel pump did so thats why I replaced mine... but ask yourself this, how many times do you access the fuel tank? It would probably be good to do it now because it really isn't that expensive and if it should go out later on you don't have to mess with the tank again. I think its worthwhile and I still would have done it if mine had not gone out... but thats just me.
Senior User
Joined: Mar 2002
Posts: 235
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From: Torrance, CA
red - makes a lot of sense. The reason I was asking was that I can find the pump at alot of parts places, but I think I'm going to have to order the sender at the dealer, and I want to get my truck running.
Just out of curiosity, how does a sender go bad? I just looks like a bunch of pipes from the pictures. Does it have any electronic functionality? How can I tell if I need a new one?
Just out of curiosity, how does a sender go bad? I just looks like a bunch of pipes from the pictures. Does it have any electronic functionality? How can I tell if I need a new one?
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Joined: Jun 2004
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I don't know why senders go bad... its just a part of life I guess... you know taxes, death and bad sensors. I just replaced a whole slew of them... O2 sensor, throttle position sensor, air charge temperature sensor, etc... Its a pain in the A$$ but it if it has to be done, you gotta do it.
Some sensors you can check for resistance with a voltmeter and others require specialized tools to test.
Some sensors you can check for resistance with a voltmeter and others require specialized tools to test.
Senior User
Joined: Mar 2002
Posts: 235
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From: Torrance, CA
red- even though you posted some pointers as to how to change the fuel pump, I have to confess that I gave up today... first off
1. Had a full tank of gas - bought 2 containers at $20 a piece (and someone actually stole one... ) and filled up my nissan, and two of my neigbors cars... siphoning took the entire morning.
2. I bought a new assembly from Ford. Figures they have a new piece out that I had to solder on.... Wasn't up for soldering next to a gas tank.
3. The clincher was - I was trying to loosen up the bolts on the fuel tank. Got some loose. But then noticed that the back side of the fuel tank is the same as the front, and I could get my wrenches in there. I needed air tools, which I didn't have and was not going to buy.
I towed it to the shop I always go to, and they all laughed, but gave me a lot of credit for trying!
We'll I'll update you all tomorrow to see if it really was the fuel pump
1. Had a full tank of gas - bought 2 containers at $20 a piece (and someone actually stole one...
) and filled up my nissan, and two of my neigbors cars... siphoning took the entire morning.2. I bought a new assembly from Ford. Figures they have a new piece out that I had to solder on.... Wasn't up for soldering next to a gas tank.
3. The clincher was - I was trying to loosen up the bolts on the fuel tank. Got some loose. But then noticed that the back side of the fuel tank is the same as the front, and I could get my wrenches in there. I needed air tools, which I didn't have and was not going to buy.
I towed it to the shop I always go to, and they all laughed, but gave me a lot of credit for trying!
We'll I'll update you all tomorrow to see if it really was the fuel pump
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sorry to hear that... could have saved a penny doing it yourself but least you tried... as for soldering connections, never heard of that one before and I guess thats why I crimped mine with the connections the pump came with. As for air tools go, I didn't use any and I didn't think it was that hard as a good 1" dia. steel pipe extension was all the leverage that I needed. Just out of curiosity, how much is the shop going to charge you?
Senior User
Joined: Mar 2002
Posts: 235
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From: Torrance, CA
red - dunno about the prices yet - but I'll let you know tom!
well the bolts i were referring to were to start off the fuel tank undercover mounting nuts that were like 14mm underneath on 13mm bolts. Unless I am a complete moron, i have to hold the bolt with a monkey wrench and use the ratchet for the nut right? Well ends up as I was looking around that I could've managed for the front side, but no way for the rear side of the tank. Thanks when I sort of gave up.
Sounds like an excuse, but I really did try. But man, did my truck look nice as it was being towed - it looked like it was going to run over the tow truck. tow truck driver loved my truck too.
well the bolts i were referring to were to start off the fuel tank undercover mounting nuts that were like 14mm underneath on 13mm bolts. Unless I am a complete moron, i have to hold the bolt with a monkey wrench and use the ratchet for the nut right? Well ends up as I was looking around that I could've managed for the front side, but no way for the rear side of the tank. Thanks when I sort of gave up.
Sounds like an excuse, but I really did try. But man, did my truck look nice as it was being towed - it looked like it was going to run over the tow truck. tow truck driver loved my truck too.