fuel pump replacement
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New User
Joined: Sep 2006
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From: Ridgeville,S.C.
fuel pump replacement
I'm new to FTE site but wanted to give a huge "thank you" for you guys sharing some good advice and mechanical know-how. I had found a fuel leak which looked as though it was coming out from under the right side of the fuel pump. As it turned out it was coming out of the weep hole. I contacted my local Ford dealer and they wanted $400 labor to replace the pump. But after reading thru the FTE forum(1994.5-1997 7.3L Power Stroke Diesel), the articles I read gave me enough confidence to attempt the repair. Took 6 hours, but have no leaks and the valley is dry for the first time in months. Thanks again for all the great articles.
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1997 Stroker, I'm attempting to change out my fuel pump also, I have a 97 PSD with a manual 5 speed trans. I have tried but been unseccesful in removing the banjo bolt, would pass on some of what you learned? I took a 1 and 1/16 box wrench ansd modified it but obviously not correctly, cant get a socket on either. And hoe did you get the banjo threaded back into pump without removing the turbo ? Thanks
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Joined: Sep 2006
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From: Ridgeville,S.C.
97psdtr, I will gladly try. The wrench you need is an 1 1/4" box end and I bought mine at Napa for $14. It needed no bending or modification. As you are facing the fire wall turn the wrench to the right to unloosen it. Installing the Banjo bolt was tedious but being patient, it went in. Put one of the gaskets on the bolt first, then I held it between two fingers and pushed it in until it just was at the front side of the bango fitting then installed the second gasket, with a long pair of pliers. Then pushed it the rest of the way until it met the threads with my other hand and then started it turning. It went almost all the way in by turning it with my fingers. The turbo did not need to be removed. Hope this helps you, good luck
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1997 Stroker, this is a California model with a disc,(accumalator I'm told) mounted on the top of the fuel pump houseing directly over the banjo bolt, is there enough clearance to lift the pump out of the valley with the base of the turbo directly over it?, if it does that would be great. Also did you unbolt the fuel filter canister and slide it towards the grill removing two of the three fuel hoses then the third after it has slid forward? thanks for your help,tom...
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Joined: Oct 2003
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From: MICHIGAN
Bad news, With Cali trucks you must remove the turbo to replace the fuel pump. Good new, you have bigger injectors than the non cali trucks.
FYI: The disc on top the is a damper. It stops fuel pressure pulses from the pump.
FYI: The disc on top the is a damper. It stops fuel pressure pulses from the pump.
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New User
Joined: Sep 2006
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From: Ridgeville,S.C.
97psdtr, oops thought you're truck was set up like mine. This was my first fuel pump replacement. If you have a Cali truck with the disc above the fuel pump, from what I read in the forum you must remove the turbo. But for sure,, once you take the turbo off, it'll be easy to get the banjo bolt out and back in. And yes I did move the fuel filter housing forward and tied it out of the way, up to the hood latch. I also replaced all the blue hoses with new ones while they were out. Good luck with you're job.
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