Replacing Fuel Pump
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Freshman User
Joined: Jan 2006
Posts: 27
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Replacing Fuel Pump
OK. I goofed up and I now need to replace my fuel pump (don't ask). Anyway, I'm about to get started when I see that the lines are held on with connectors my wrenches don't fit. A mechanic gave me the tool to remove the connection but now I'm concerned about having enough hands to do the job. I'm imagining myself on my back with one hand over the fuel line from the tank, one hand over the fuel line from the engine and trying to replace the leaky pump with my teeth. 
Has anyone else replaced their pump? How do I keep from leaking diesel all over my driveway while I put in the new pump?
Has anyone else replaced their pump? How do I keep from leaking diesel all over my driveway while I put in the new pump?
Post Fiend
Joined: Jul 2005
Posts: 14,582
Likes: 12
From: 21791
spread out some plastic on the ground below your truck. i use cardboard because i can burn it once im done, and it soaks up oil and fuel pretty well. the connections are "quick disconnect", which do well under pressure, but not under vacuum. just slide the tool over the inlet, and push towards the fitting. it will pop off. other than that, it is just swapping wires and pushing the ends back on. easy, but i have not done mine. a good mod to do at the same time is to eliminate all (two) of the quickdisconnects on the "pre-pump" side of the pump. this way no air can get in past the Q/D fitting. search for "hutch mod" or "quickdisconnect elimination. then it WILL accept a tool you have, which is a flat screwdriver for the hose clamp(s)
Fleet Mechanic
Joined: Jun 2004
Posts: 1,296
Likes: 1
From: Coal Valley, Illinois
It helps if the fuel level is low. If the fuel level in tank is below the lowest point of the lines/pump, the fuel won't siphon out and spillage and mess are kept to a minimum. Good luck. 
Steve
Steve
Senior User
Joined: Mar 2006
Posts: 204
Likes: 0
From: Michigan
So to eliminate the QD you just cut it off and reassemble with a hose clamps 180 apart or do you also need new line?
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Fleet Mechanic
Joined: May 2005
Posts: 1,567
Likes: 3
From: Chattanooga
U dont really have to cut anything at the pump, just place hoses in place of the connection or just replace the whole line. I had to change mine on the side of the road week before last. 325 bucks and a whole lot of fuel on me. I couldnt get the front disconnect off so I just unscrewed it and swaped it for new. Thats all I could do on the side of the interstate. Im going to go to the tractor supply and put a screw on filter and possibly another cheap fuel pump on prefilter and pre original pump.
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Brett Foote
Senior User
Joined: Mar 2006
Posts: 204
Likes: 0
From: Michigan
Thanks for the clarification. I am trying to get all this info from overseas so when i get home i can get it all done in the 2 weeks I'll be there. I have the Hutch mod pictures but still foggy on from there to the pump. I hate not being able to just go out and look under the truck at it myself. Do you have a recommendation on a supplier for the SS lines and connectors for the hutch mod?
hutch mod pro's and cons
Senior User
Joined: Mar 2006
Posts: 204
Likes: 0
From: Michigan
The mod is to keep air from entering the fuel lines from inside the tank. From what I understand the QD's external to the tank with allow air to enter the lines under vacume but not under pressure so that is why the removal of the QD's before the pump is required, after the pump they are under pressure from the fuel being pushed instead of pulled. Please someone correct me if I am wrong as this is new to me.
Elder User
Joined: Nov 2005
Posts: 796
Likes: 0
From: North Idaho
Check this out . Some excellent pictures and a parts list for the Hutch mod.
http://guzzle.rbmicro.com/hutch.htm
http://guzzle.rbmicro.com/hutch.htm
Post Fiend
Joined: Jul 2005
Posts: 14,582
Likes: 12
From: 21791
yes. all of the above ideas and hypotheses are correct.
luvemhot- yes disconnect the one at the inlet of the pump too. i would replace the entire line (i did) from the hard steel hose on the frame to the rubber line going to the pump. double hose clamps and then i smashed the QD at the inlet of the pump with vise grips and a screwdriver, i had broken my QD tool and i didnt want to go out again. plus i was never going to use that again.
62trvler- yes just replace the line and double clamp it. i will go out and grab a few pics here soon. and add them to my gallery. i didnt take pics as i did the mod, i was all dieseley and i didnt want to screw up mom's cam.
toolboxjunky- yes 62trvler had it in the post after you. strictly to eliminate air as much as possible. so the lack of air in the "dead end" fuel system really quiets the engine and makes it run alot smoother. air is a killer of any diesel injector.
here is the place where i got my in-tank and prepump modification kit. ITP diesel. hmm checked their site, but it's not in the Fuel system category. buti got mine there. call and ask them about the Prepump and intank fuel kit.
luvemhot- yes disconnect the one at the inlet of the pump too. i would replace the entire line (i did) from the hard steel hose on the frame to the rubber line going to the pump. double hose clamps and then i smashed the QD at the inlet of the pump with vise grips and a screwdriver, i had broken my QD tool and i didnt want to go out again. plus i was never going to use that again.
62trvler- yes just replace the line and double clamp it. i will go out and grab a few pics here soon. and add them to my gallery. i didnt take pics as i did the mod, i was all dieseley and i didnt want to screw up mom's cam.
toolboxjunky- yes 62trvler had it in the post after you. strictly to eliminate air as much as possible. so the lack of air in the "dead end" fuel system really quiets the engine and makes it run alot smoother. air is a killer of any diesel injector.
here is the place where i got my in-tank and prepump modification kit. ITP diesel. hmm checked their site, but it's not in the Fuel system category. buti got mine there. call and ask them about the Prepump and intank fuel kit.
Post Fiend
Joined: Jul 2005
Posts: 14,582
Likes: 12
From: 21791
went outside with the camera, the thermometer read 97*, blacktop was alot hotter than that. too hot to walk on barefoot, not to mention to lay on your back and snap pics. i will do it later on when it cools down some.