Well after 7 years and 215,000 miles my son's 2001 F-250 V-10 died in the driveway. After diagnosing the problem, checking DTC's, fuel pressure, etc. we determined it was the fuel pump. We decided to pull the bed off rather than dropping the tank because it seemed easier. The bed came off really easy with 8 bolts, wire harness connector, and fuel filler disconnected. We moved the bed back about 2 feet and left it resting on the tires and the rear bumper. This exposed the pump/sending unit just behind the cab. Using a really big pair of channel locks we carefully unscrewed the big plastic lock ring after disconnecting the 2 fuel lines and the pump connector and removed the pump cover. To our surprise (and disappointment) we had to drop the tank a little to facilitate removal of a wire pigtail running to what appeared to be a vent at the rear of the tank. The main part of the fuel pump/sending unit fits into fixture at the bottom of the tank secured by 2 clips. It helps to have 2 people and 4 hands to fish this octapus looking assembly out of the tank. When you go to the Ford dealer to get the new pump it helps to have the VIN as you have to know the wheel base of the truck that the dealer can ascertain from the VIN. Putting the new unit in is pretty straight forward. Just be sure to unclip the new sending unit float arm so it swings freely before putting the lid back on. Otherwise the unit reads empty and the "low fuel" light stays on. (Ask me how I know). It also helps to use a little soapy water on the plastic ring so it screws on easier. Then it's just matter of bolting the bed back on and re-connecting everything back up. During the re-assembly it gives you time to ponder the question "Just why in the hell doesn't the factory mount a remote fuel pump in the frame rail so it can be easily replaced instead of putting it in the tank"??????

 

Nice report... sorry about your issues

I wonder myself about where the fuel pump goes - but I think it's cooling (immersed in liquid is a good thing), and priming.

I have to do something about the evaporative control (vapor/vent line) leaking - as in, fill to the top, it overflows gas under the truck, it doesn't click off the fillter nozzle.

Wondering what to do - looks like dropping the tank is probably the best.

 

Excellent post paul... I'll hope to learn from your troubles the first time I have to drop my tank! Rep points on the way...

Sorry for your issues, but I hope it makes you feel better knowing you passed on some very valuable tips! I'll buy you a beer if you ever come through Riverton!

 

another easy tast to re installing the big plastic ring is to put it in a pan of boiling water, so it expands, then it goes on sooo easy. But like eveyone else, live n learn. Glad everything turned out ok. At least you had a bed to remove, I couldnt take the rear of the excursion off when I did mine. But at least it was in the summer time and not the middle of winter.

Brian

 

Thanks for the info, great post.

 

The few times I've done the fuel pump on various vehicles, I hook up a Holley electric fuel pump I have from an old project, to the fuel rail. I take out the Zerk fitting, and just hose-clamp 5/16" or 3/8" fuel line to it. Turn on the fuel pump, and pump all the gas right out of the tank.

It's much easier without any gas in the tank