Replacing the fuel tank.
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Fleet Mechanic
Joined: Feb 2003
Posts: 1,314
Likes: 35
Replacing the fuel tank.
1989 F250 - replacing the rear fuel tank pump (sending unit went bad)
Undid the bottom 2 straps. That wasn't too bad, except that the bolts were rusty.
Then, the tank didn't just drop down as I thought it would. I had to undo the filler neck hose. In 3 places. First, right where you put the gas in, second, where the metal neck meet the hose going to the tank, (probably not necessary) and third, where the hose meets the tank. Then I had to make sure the hose moved along with the tank. The tank just wouldn't drop otherwise. It was a pain.
Dropping it after removing the straps was the major part of the job, it also didn't have enough clearance on the right side, getting caught on the exhaust pipes.
I have the tank nearly dropped now, and will swap the fuel pump soon. Do I need a special tool to disconnect the fuel lines? Anything else I need for this?
I hope I never have to do this again, it sucks.
Undid the bottom 2 straps. That wasn't too bad, except that the bolts were rusty.
Then, the tank didn't just drop down as I thought it would. I had to undo the filler neck hose. In 3 places. First, right where you put the gas in, second, where the metal neck meet the hose going to the tank, (probably not necessary) and third, where the hose meets the tank. Then I had to make sure the hose moved along with the tank. The tank just wouldn't drop otherwise. It was a pain.
Dropping it after removing the straps was the major part of the job, it also didn't have enough clearance on the right side, getting caught on the exhaust pipes.
I have the tank nearly dropped now, and will swap the fuel pump soon. Do I need a special tool to disconnect the fuel lines? Anything else I need for this?
I hope I never have to do this again, it sucks.
Elder User
Joined: Jul 2003
Posts: 935
Likes: 0
From: TEXAS!!!!!!!!!!!!
well you either have the the fittings like on airconditioner lines or you have the little white clips. Mine, luckily has the clips. It might just be on the fuel filter, i havn't looked at the part on the tank.
go here http://fordfuelinjection.com/index.htm then go to the tools section it has pics.
go here http://fordfuelinjection.com/index.htm then go to the tools section it has pics.
Junior User
Joined: Jun 2004
Posts: 84
Likes: 0
From: San Jose CA
Tip on replacing fuel tank pump
I had the pleasure of replacing the in-tank pump in the rear tank of my '91 F250 4x4 several months ago. My biggest issue was with getting the fuel supply and return lines attached to the tank properly, without kinks or leaks.
The first time I thought I had it right, until right after I started it up to test it. I was running on the rear tank, to test the new pump. I had a full front tank, and had dumped a few gallons from a jarry can into the rear tank. As I backed out of the driveway, I saw gas pouring out of the front tank filler. It stopped when I switched to the front tank. As it turns out, I had kinked the return line when replacing the tank into position, and thus the return fuel from the rear tank went to the front tank instead. Since the front tank was full, within a minute or so it overflowed. The pump puts out quite a bit of fuel, so at idle most of it is returned.
Watch the fuel line connections when you move the tank back into position after you connect the lines!
Hope this helps, Dave
The first time I thought I had it right, until right after I started it up to test it. I was running on the rear tank, to test the new pump. I had a full front tank, and had dumped a few gallons from a jarry can into the rear tank. As I backed out of the driveway, I saw gas pouring out of the front tank filler. It stopped when I switched to the front tank. As it turns out, I had kinked the return line when replacing the tank into position, and thus the return fuel from the rear tank went to the front tank instead. Since the front tank was full, within a minute or so it overflowed. The pump puts out quite a bit of fuel, so at idle most of it is returned.
Watch the fuel line connections when you move the tank back into position after you connect the lines!
Hope this helps, Dave
