Ok, I know this is somewhere in over hundreds and hundreds of postings, but I'm not finding anything right away, so someone please point me in the right direction. I'm looking for a "how to" on the installation of a fuel pump in the front tank of a 1996 F150 4x4 with a 5.8L. I'm not sure how long it will take, and I also want to make sure I've got all the tools I'll need for the job. I'm kinda stuck once I get beyond the obvious of removing the skid plate and dropping the tank. The new fuel pump had "instructions" but I would prefer a little more detail or maybe even a diagram. I have seen several threads that refered to the pump relay. A little info on where I need to check these things would help as well.

Michael
1996 F150 XLT
Ext Cab, 5.8L
4x4

 

Try a Haynes manual available at your local parts store for instructions. Dropping tank can take a while and works - you will need tool to disconnect fuel lines get the scissors type, worked best for me. Be prepared to support tank and whatever gas is in it - floor jack and boards and get a piece of brass stock to loosen lock ring on pump sender unit. No sparks!
An alternate method that I haven't tried personally but requuires less interference removal on tanks is to remove the bed; then the only thing to disturb on the tank is the pump sender unit (and gas lines). Just spare tire, wiring and the bed bolts in best case - no camper shell or bed full of equipment. Lots of variations exist.
Comments from those experienced I am sure would be welcome.
Good luck!

 

A previous owner of the truck installed a spray-in bed liner. I would think that could be an issue with removing the bed. I wouldn't want the bolts to punch though from underneath the liner if they had any type of pressure put on them. If I'm going to the local parts store/tool store to get the fuel line disconnect tool, then I might as well pick up a manual. Any idea on how long of a job this would take? I'm guessing at least 2-3 hours at a careful pace.

 

Dropped my tank last year to change out my pump...95X15 hit all the major points for pump replacement, but here's a little more detail on how I did it...

1. Get LOTS of rust buster/pb blaster/whatever and soak the bolts a few times a day for several days before you get to work. Hopefully, you'll be able to get the bolts off easier than I did.

2. Get a floor jack and some blocks of wood to support the tank while working on the bolts. The tank is held up by two straps (four bolts you need to take off). If you're lucky, you'll be able to muscle off all four bolts. If you're unlucky (like me) you'll strip a bolt thread or nut or two, and have to find an alternative method of getting off the bolt (I managed to wedge a recip saw under there and, three blades later, cut off the bolt head). Be sure to wear some safety glasses, of you'll be picking dirt out of your eyes forever...

3. After the bolts and straps are loose, remove the rubber filler neck from the gas fill door - I believe it's just held on by a gear clamp. You can then start to lower the tank. Drop it a few inches - enough to get your hands up top - then unclip the wiring harness and, using your fancy tool, disconnect the fuel lines. The tank should now be ready to drop fully.

4. Now that you've slid the tank out fron under your truck, you can remove the fuel sending unit. Take a hammer and a BRASS punch and remove the locking ring from the tank (remember, as 95X15 said, there are fuel vapours lingering, and you don't want to cause any sparks). The old fuel pump assembaly should then lift right out. Replace it with your new one, and reverse directions to get your tank back together. The hardest part I had with re-assembaly was with the filler neck - it has an inner and outer hose, And I had a heck of a time sliding them back in one another. I eventually used WD-40 to help slide the hoses in. MAKE SURE you don't kink the inner hose, or you'll never be able to fill the tank with gas (trust me). I also suggest using some stainless steel bolts and lock washers when re-attaching the straps, just in case (god forbid) you have to drop the tank again in the future.

Hope this helped some, I'm sure it'll make more sense when you start digging into it. If I've missed anything, hopefully someone else here will pipe up...

Good Luck,
Gregg

 

pressure washing under the truck will help to. Run the fuel tank down to 1/4 tank.

 

It's relatively easy if you have help. Get a buddy to hold the tank while you wrench, or vice-versa. that's what I did.

I suppose a jack will do the same thing.

 

Remove the bed! Just kidding. That's how I'm doing mine, but then again I'm painting it right now and the bed is already off. I think it may just about be easier, as long you have 4-5 buddies to help.

 

There's are alot of people that found it easier to remove the bed.