Nice pic, there you see the metal disk with the metal hoses and pig-tail coming out of it, that is what I'm talking about. Neither the pump or sender comes with it. The pump cliks onto the metal hoses at the bottom and you have to attach its (the pumps) wires to the pig tail with crimp connects. The sender screws to a tab mounted to the metal hoses. Remember you need one from a Bronco tank the F-150 one is too short. You'll have alot of gas in the tank but, the pump won't be able to reach it.

Ok the reason the aftermarket 38 gal, and the 45 gal for that matter, won't work is the hole in the tank for the pump and sender assembly is too small or big( I can't remember). The other tanks mentioned if they are for the 5.4 or 6.8 that means they are for a completely different truck ie. not our bodystyle or age. So they won't be the right size for our frames.

 

I was talking about the 89 era (I'm sure sure what years). Some of the F-250 (and E-250s for that matter) had 38 Gallon tanks. And Some company came up with a kit you could use that would extend or replace the pickup tube, and adjust the float. This was on the stock fuel pump. PLus it said you only need bigger tank straps for the bottom and it was otherwise drop in parts. If it worked it would be much more desirable to a bronc tank as you don' have to mess with the chassis, or worry about bumps.

 

The E-series were all long tanks.None of them came with a rear tank like a Bronco.

 

My guess would be that you'd still have to watch for bumps either way and still have to move the spare. Ya using a Bronc's tank you have to make another crossmember but that's it, and way easy, but by saying you have to "mess with the chassis" makes it sound difficult. Plus Broncos are way eaisier to find in a bone yard than a F250 with the optional 38gal tank and finding that kit you referr to. Not to mention the problem that '89 and '94 pumps are not interchangeable due to emmisions.

 

Good point. I would say that I'm thinking from a 89 Point of view, thats my truck. Uh.... I'll look for the link I found. I found it and it is older. Never mind.

 

Lol, not a prob.

 

Yeah.My 90 Bronco tank that I got the other day was washed off really well and the skid plate was fixed in a couple spots.I pulled the fuel pump out to look inside. The old fuel stunk and there was a little bit of stuff in there but nothing bad. The pump had a aftermarket pump in it that was siezed so I ordered and new complete fuel pump from Ford.The pump is the same from 1990-1996. I should be installing the Bronco tank this weekend after I get my crossmember. I will get some pics for you if you still need them.

 

One thing for me to add....

the "sending unit" includes the feed and return tubes, the wiring, and mounting flange that attaches to the fuel pump and the tank to hold it in place. The sending unit is not just the float lever portion. The fuel pump is the plastic case portion, where the actual pump is inside it with the check valve and other crap.


Hope that helps.

 

When I ordered two different sending units neither of them came with the flange. So I figured that's all it came with.

 

You have a fuel pump and then you have the sending unit that bolts to the pump.

 

Well there is no other separate part. That system consists of a sending unit and a fuel pump and that is it. I guess it makes more sense to call the sending unit the float and sensor portion only but the rest is included.

Whoever you bought it from simply didn't include it and that is not the norm.

 

NAPA and CarQuest

 

And in LMC it only comes with the metal part up to '89

 

I ordered mine from LMC truck for my 95'.

Most local parts stores to not sell it like that because it is unusual that you'd replace that portion of the sending unit.

I work at a parts store and most other applications we sell do have the entire sending unit because you can't take it apart like you can on the ford.

 

Ok.So I did the swap today and man was it simple.

After I removed the old leaking tank I was able to see what I was doing. I put in a new fuel pump in the Bronco tank and mocked it up. I used angle iron cut at 36 3/4" length. Then I put it between the frame rails.It lined up perfectly with the middle bolt holes on my trailer hitch.I drilled the holes for the trailer hitch into the new crossmember and bolted it down. Then I lined the holes for the rear skidplate to the rear crossmember. Amazingly the front crossmember already had pre drilled holes for the Bronco skid plate.After I did a few mock up attemps,I put it all together and bolted it down.Spliced the wiring for the new Ford pump(required if you buy a new Ford fuel pump).After I completed the install I went to the gas station and spent $1 per litre on filling the rear tank from a dead empty to full.As I was filling the tank I kept looking under the vehical to see if there was any leaks.At the $100 mark I was really wondering where all the fuel was going because it was still filling and there was no leaks.I was glad when it did finally stop at $118.50. Now that was just the rear tank. Add another $55-$60 for the mid tank and that is what it costs to fill my truck.WOW!!!!!!!

Some notes to put in. This was a very easy swap to do, for me. I had a hoist, trans jack, fuel tank suction barrel and the best air tools money can buy (I am a Ford Technician).I did the swap from start to finish in about 2-1/2 hours.This job on your back on the garage floor will take a long time and be messy

Now the simple fix problems I encountered on the way.

#1: I had to notch the front left side of the skid plate to have space for the brake hose.It comes down from the front L/S of the crossmember to the axle.The skid plate from the Bronco hits it and will cut the hose if bolted down. Now I cut it but it could be bent in that corner if you wanted to.

#2: The vent port at the top of the Bronco tank may be different from your F-150 tank. I swapped my vent valve and hoses from my F-150 to the Bronco tank.This is a simple plug and play.Some may not need to swap it but I did because it had 1 hose to the purge canister and the second hose was a fresh air hose. The Bronco tank just came with a 1 hose to the purge canister line.

#3: You will have to find a new place to put your spare tire. I know there used to be some kits that bolted the spare inside your truck bed. I don't know if they are still available but don't forget the spare tire. The time you forget it WILL be the time you get a flat in the middle of nowhere!!!!!!!

That was it. I have 2 guys at work with F-150's that were watching me do this swap and are interested in seeing the results since I may be doing this to there trucks soon. Anyone wanting to attemp this swap can feel free to ask me any questions.

P.S. I did not get any pics because this was a real easy swap to do.I will get some tomorrow of the end result so you can see how she looks.

Thanks to towmanjbo for the pics he did post and the info that he passed on.