Fuel Pump Questions
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Senior User
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Fuel Pump Questions
Hello,
I am going to try and tackle my fuel pump this weekend. I have the big long write up that I found on here, but I just have a couple quick questions. How should I turn the engine over to lift the fuel pump out to make sure that the tappet doesnt fall down?. Secondly, I can reach the banjo bold without bending a wrench, Am I missing something? Maybe that isnt the banjo bolt? Big *** 1 1/4 " Bolt?
Thanks
Derek
I am going to try and tackle my fuel pump this weekend. I have the big long write up that I found on here, but I just have a couple quick questions. How should I turn the engine over to lift the fuel pump out to make sure that the tappet doesnt fall down?. Secondly, I can reach the banjo bold without bending a wrench, Am I missing something? Maybe that isnt the banjo bolt? Big *** 1 1/4 " Bolt?
Thanks
Derek
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Joined: Aug 2006
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Originally Posted by Dstosh
Hello,
I am going to try and tackle my fuel pump this weekend. I have the big long write up that I found on here, but I just have a couple quick questions. How should I turn the engine over to lift the fuel pump out to make sure that the tappet doesnt fall down?. Secondly, I can reach the banjo bold without bending a wrench, Am I missing something? Maybe that isnt the banjo bolt? Big *** 1 1/4 " Bolt?
Thanks
Derek
I am going to try and tackle my fuel pump this weekend. I have the big long write up that I found on here, but I just have a couple quick questions. How should I turn the engine over to lift the fuel pump out to make sure that the tappet doesnt fall down?. Secondly, I can reach the banjo bold without bending a wrench, Am I missing something? Maybe that isnt the banjo bolt? Big *** 1 1/4 " Bolt?
Thanks
Derek
Postmaster
Joined: Aug 2004
Posts: 3,948
Likes: 2
From: SHELTON, WA
24mm socket and 3/4 drive ratchet on the front of the crank. turn it over slowly. good luck with the blue hoses they suck. its do able but once you do it you swear the next time it goes your going electric fuel pump. my hands got eaten alive by the pedistal. if i where to do it again i think i would re use my old banjo gaskets also. seeing how mine where stuck onto the fitting on the fuel line already i should of never pried them off. trying to get the banjo bolt back through and get those seals to stay lined up in that tight space is a chore.
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Joined: Sep 2007
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I do believe that I followed the same long list of instructions that you have. I did not need to bend any tools. Throw a towel over the top of the radiator and get comfy. Patience is your key. Take your time and follow the instructions, they are right on. I don't know if I would re-use the gaskets, but I can vouch for the fact that they are a pain to keep aligned while starting the banjo bolt. I went slowly, and carefully because this is my first diesel truck and did it in 3 hours out in a gravel driveway. The instructions and input from users of this site were invaluable and are helping to build my confidence in repairing my own diesel vehicle. Hats off to all the knowlegable folks that take the time to post.
Senior User
Joined: Sep 2006
Posts: 161
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From: Indiana
I took my front tires off and lowered the jack stands so the rotors were just above the ground. Helped a little with height issue.
You can reanneal the crush washers with a propane torch. I don't suggest doing this over new ones, but in a pich I have had good luck with it many times on various things. Heat up the copper till it turns red hot and changes to magic colors as you pass over it with the flame (you'll see it). This softens the metal and makes the washer flat again. Never had any luck with aluminium, if thats what you got on there.
I never turned my motor over to lift the pump. I was really worried about the push rod, but all the diesel fumes and broken and bruised ribs "made" me just pull the pump right out with luckily no problems. I had a magnetic wand right next to the hole where the push rod was about to appear ready, but this was a stupid idea nevertheless; don't take any chances.
I used the words Magic and wand in this post. Wierd.
You can reanneal the crush washers with a propane torch. I don't suggest doing this over new ones, but in a pich I have had good luck with it many times on various things. Heat up the copper till it turns red hot and changes to magic colors as you pass over it with the flame (you'll see it). This softens the metal and makes the washer flat again. Never had any luck with aluminium, if thats what you got on there.
I never turned my motor over to lift the pump. I was really worried about the push rod, but all the diesel fumes and broken and bruised ribs "made" me just pull the pump right out with luckily no problems. I had a magnetic wand right next to the hole where the push rod was about to appear ready, but this was a stupid idea nevertheless; don't take any chances.
I used the words Magic and wand in this post. Wierd.
Post Fiend
Joined: Oct 2003
Posts: 5,903
Likes: 1
From: MICHIGAN
Originally Posted by pstroke7_3
I do believe that I followed the same long list of instructions that you have. I did not need to bend any tools. Throw a towel over the top of the radiator and get comfy. Patience is your key. Take your time and follow the instructions, they are right on. I don't know if I would re-use the gaskets, but I can vouch for the fact that they are a pain to keep aligned while starting the banjo bolt. I went slowly, and carefully because this is my first diesel truck and did it in 3 hours out in a gravel driveway. The instructions and input from users of this site were invaluable and are helping to build my confidence in repairing my own diesel vehicle. Hats off to all the knowlegable folks that take the time to post.
, you already discovered how great this site is for help. Good job on the FP, it's a PITA but the write-ups here make it tolerable. IF you followed the factory repair manual it would have you removing the turbo 
.
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Post Fiend
Joined: Oct 2003
Posts: 5,903
Likes: 1
From: MICHIGAN
Originally Posted by audimaster
I took my front tires off and lowered the jack stands so the rotors were just above the ground. Helped a little with height issue.
You can reanneal the crush washers with a propane torch. I don't suggest doing this over new ones, but in a pich I have had good luck with it many times on various things. Heat up the copper till it turns red hot and changes to magic colors as you pass over it with the flame (you'll see it). This softens the metal and makes the washer flat again. Never had any luck with aluminium, if thats what you got on there.
I never turned my motor over to lift the pump. I was really worried about the push rod, but all the diesel fumes and broken and bruised ribs "made" me just pull the pump right out with luckily no problems. I had a magnetic wand right next to the hole where the push rod was about to appear ready, but this was a stupid idea nevertheless; don't take any chances.
I used the words Magic and wand in this post. Wierd.
You can reanneal the crush washers with a propane torch. I don't suggest doing this over new ones, but in a pich I have had good luck with it many times on various things. Heat up the copper till it turns red hot and changes to magic colors as you pass over it with the flame (you'll see it). This softens the metal and makes the washer flat again. Never had any luck with aluminium, if thats what you got on there.
I never turned my motor over to lift the pump. I was really worried about the push rod, but all the diesel fumes and broken and bruised ribs "made" me just pull the pump right out with luckily no problems. I had a magnetic wand right next to the hole where the push rod was about to appear ready, but this was a stupid idea nevertheless; don't take any chances.
I used the words Magic and wand in this post. Wierd.
If you want to soften aluminum use an acetalene torch. Use just acetalene first to blacken the aluminum with soot, turn on the oxygen and carefully burn off the soot. When the soot disappears the temp of the aluminum is annealed. This is the best method for the thin stuff so it doesn't turn into a puddled.
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Thread Starter
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Senior User
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I got her changed today. It wasn't to bad thanks to the write up. The hardest part was all of the stupid little 3" hoses. The pump that I took out was the same one that I put in,Carter : Leads me to believe that It was changed before.
Thanks
Derek
Thanks
Derek
Post Fiend
Joined: Apr 2004
Posts: 12,835
Likes: 3
From: Silver Lake Dunes, MI
carter is the only company making pumps for our trucks last time I heard. Ford and Napa I know for a fact are Carters and many other have reported the aftermarkets they bought were carter. so it may or may not have been changed.
But anyway glad to hear it went good for you.
But anyway glad to hear it went good for you.
Thread Starter
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Senior User
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Interesting. Thanks for the info. After re reading this post, I believe I put the Banjo Gaskets on incorrectly. I Put both on the bolt, One is supposed to go on the bolt, the other is supposed to go between the pump and the spacer deal. DOH
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