I have got a 97 E350 Van with 7.3 Turbo Diesel. I am replacing Fuel Lifter Pump. This is a straight shaft pump. Drive Cam was in down position when I tried to install. During Installation the shaft/plunger on the Fuel Lift Pump broke off (or fell of if it isn't a solid piece) and went into the motor cavity. I tried to get it out by felling around with my small magnet but I heard it drop pretty far down ( it went clunk, clunk, clunk.....so I think it went almost to the oil pan). I drained oil and felt around with a wire but didn't find anything.

Here is the question....how far down can it fall and if it did fall pretty far down but not to the oil pump will it hurt anything? I'm assuming that the cam isn't going to be hurt and that it is probably resting just above the oil pan.....or if their is a oil pan shield....it is probably there. I even took a rubber happer and hit all around the oil pan but nothing is rattling around. Do I need to pull motor?

Also, is the shaft typically loose on the Fuel Lifter Pump or did it just break?
Thanks for any advice.

 

Man that is not good the shaft did not break it is loose in the fuel pump, when ever you do one yu have to be extremly carefull not to do that. I dont think it will fall to the oil pan but you have to hope it did because that will tear anything and everything up. I just did mine and since it was worn the shaft barly stayed in but with the new one it stayed in tight. Keep trying to get it out with a magnet and a stick, but what you need to do if you cant get it with the magnet, drop your oil pan and search for it there you might find in the setting there but be thero with you search good luck and keep us posted

 

Try turning engine over with a breaker bar on crank pulley. If u can get to fall down in the pan u can do two things put a magnet on pan to hold it in place or remove the dipstick tube be careful not to loose the lower nut on dipstick tube. It will do no damage if u leave it in the pan. There are several guys on this forum running with the plunger in oil pan. Hope this helps and good luck. Jeep

 

Hey that a good idea with the magent thing dont do more work if you dont have to right!

 

It could be sitting on the windage tray in the oil pan. Rotating the engine by hand is a good suggestion. Keep the oil drained until you are able to figure out where its at. I think the magnet trick is a good fix until you have the need or time/money to pull the engine. Also some have cut a hole in the side of the pan to retrieve them. If you know a good welder this is a good option on as well.

 

Okay...I got my E350 Van running. I never did find the Lifter Pump Rod. Rod is not part of the Lifter Pump but is a separate piece that just pushes up into the bottom of the Pump. The following is some helpful information to everyone in the future.

When replacing a Fuel Lifter Pump make sure you are very gentle when removing the old one because the pump body that fits down into the engine cavity is cast (non metalic) and it will break off quite easily. The Lifter Pump Rod will also fall down but is metallic. If it does fall down try the magnet but good luck. The best luck I had was to knock it off the cam and make it fall down to the bottom of the engine. Past posts on this site show a lot of similar experiences where the pump rod just falls or eventually falls to the oil pan. You cannot get it out of the oil pan thru the stock drain plug.

When putting in a new Lifter Pump make sure that the cam is on the down stroke and then mount the pump tightening down the two bolts equally thruout the process. DO NOT try to put on the fuel lines until after the pump is locked into place other wise the pump rod will probably fall into the engine . The fuel lines are ridiculous to get on unless you loosen the Fuel Filter Housing (just two bolts). Then it is possible (but difficult) to get on the lower fuel line. The upper fuel lines are a breeze compared to the lower one.

Since losing my Pump Rod in my motor....I have replaced everything and started it up and drove it around without issues. I imagine that eventually it will find it's way to the bottom of the pan where it will live comfortable till the engine is rebuilt.

I hope this helps. Oh, there weren't any installation instructions in the Pump I bought from NAPA and all the mechanics I talked to locally said to just stick the pump on with no special instructions......boy were they wrong.