Ford F-150 F-250: How to Replace Fuel Pump

When your fuel pump goes bad, your Ford F-150 or Super Dutywill not drive the same. But you can replace it yourself. Here's how!

By Tony Greene - September 16, 2014
Contributors: F 150 Hub.com, Worf, Richard Ristow, thefordmaniac

This article applies to the Ford F-150 truck (1999-2014) and F-250 Super Duty (2005-2014).

If you are having trouble firing up your engine or you suddenly experience strange idling while on the road, it could be that your fuel pump is on its last legs. Your fuel pump is a component that can wither over time, usually over a long period of time. So what exactly is a fuel pump and how do you go about replacing one should you need to?

Ford F-150 or Super Duty's come equipped with electric pumps, which are designed to direct fuel from your tank to your carburetor. This component is essential to the overall performance of your vehicle. And because it's located in your fuel tank, there is no easy way to get at it. You will have to remove your truck bed or remove your fuel tank. We'll show you how to do both -- and let you pick your adventure.

Important Safety Note: Always be sure that your F-150 or Super Duty is on a flat and safe surface with the engine off prior to performing any DIY procedures. For this specific task, you will also need to drain the gas tank prior to making the repairs.

Option 1 - Removing the fuel tank

This step requires siphoning gas and using a car jack and several stands. You will also be spending a lot of time underneath your vehicle and you will need to remove all lines that connect the fuel tank to the truck itself. The biggest difficulty with this option is that some of the connections might be very rusty and tough to loosen.

(Related Video: Removing fuel tank to replace fuel pump - YouTube.com)

Material

  • Clear hose and air pump for siphoning gas
  • New fuel pump assembly
  • Car jack and four stands
  • Impact wrench
  • 1/4 inch hex socket
  • Flathead screwdriver
  • 3/8" fuel line disconnect tool (useful but not necessary)
  • Sharpie pen

Step 1 - Remove fuel from your tank

Before removing your fuel tank, you will need to be sure it is empy -- or close to empty. In order to do this, you will need to siphon the gas out using a clear hose and air pump. Please see the video below for the proper steps.

Step 2 - Elevate your truck

Figure 1. Jacking up your truck.

In order to safely work beneath your F-150, your vehicle will need to be propped at least 18 inches above the ground. Use a standard jack and place it in the groves along the frame of your truck. For trucks that are already lifted, you may have enough room to work without having to jack up your truck.

(Related video: How to Properly Jack Up a Vehicle - Youtube.com)

Step 3 - Remove the heat shield


Figure 2. Removing the heat shield.

Once your truck is safely and securely raised, grab your impact wrench and crawl under the truck. You will find that the heat shield is protecting the fuel pump (Figure 2 above). You will also notice two sets of bolts. One set holds the heat shield in place. The second set holds the fuel tank in place. You first want to locate those that hold the heat shield. They will be aligned with the heat shield strap.

Pro Tip

Be careful not to remove the bolts for the tank straps before removing the heat shield.

After removing the bolts, the heat shield will start to drop as you remove it. Place your knee against it so it doesn't fall on you as you wiggle it free. Once it is free, put it aside.

Step 4 - Remove fuel tank

Figure 3. Two jacks support the fuel tank.

Grab two floor jacks and place them underneath the fuel tank. You will need these to support the fuel tank as you remove its bolts. Be sure that the jacks are raised just enough to support the tank (see Figure 3 above). It's also a good idea to insert some soft padding between the jack stand and the tank to prevent damage.

Once again use your impact wrench to remove the four exceptionally long bolts (13mm) from the fuel tank. Once both straps are loosened, lower the straps and twist them off. Don't force them or you will wind up ruining the mounting point. Set the two straps and the bolts to the side.

Now your fuel tank should be supported only by the jack stands. Ask somebody to slowly lower the stands while you hold the fuel tank. The front end won't drop right away because it is connected to the fuel fill line. You will need a 1/4 inch hex socket to remove this connection.

Once the fuel fill line is disconnected, your assistant can lower the jack stands further and you should be able to pull the fuel tank out from under the truck.

Now move onto Step 6 - Locate and clean fuel pump module below.

Option 2 - Removing the Bed

If you don't have the tools, jack stands, or inclination to get under your truck and remove the fuel tank in order to get to your fuel pump, you may prefer to remove your truck bed instead. This is an easy process that requires you to remove the bolts that are keeping it in place, disconnect the bed and tailgate lighting, remove the wire harnesses for the bed lighting and tail light plugs, and the fuel filler cap and fuel filler neck clamp. You will also need the help of two strong friends to lift the bed off of your truck.

Material

  • New fuel pump assembly
  • Impact wrench
  • Bed hooks, two ropes, and a chain hoist - or two strong friends
  • Flathead Screwdriver
  • 3/8" fuel line disconnect tool (useful but not necessary)
  • 8mm wrench
  • Sharpie pen

(Related Video: Removing truck bed to replace fuel pump - Youtube.com)

Step 1 - Remove the bed

Figure 4. Removing bed bolts.

Climb onto the bed of your truck and use your impact wrench to remove the six bed bolts.

Step 2 - Disconnect fuel filler cap

Figure 5. Disconnecting fuel filler cap.

Remove the three 7mm bolts that hold the filler cap in place. After you loosen the cap, let it hang down.

Step 3 - Remove filler neck clamp

Climb down under the truck just beneath your gas cap (see Figure 6). You will find a clamp that connects the filler neck to the bed of your truck. Loosen the clamp so that the filler neck is loose from the bed.

Figure 6. Removing fuel filler neck clamp.

Step 4 - Disconnect bed and tail lights

You will now need to slide further underneath your truck bed and disconnect the wire harness (Figure 7 below) for the bed lighting. To find it, slide over to the left rear corner of the bed and look straight up. Pull on the two connectors until they come loose. Watch for falling dirt, which will get in your eyes if you don't wear goggles! Slide the two ends of the wire harness out of the way and let them hang loose.

Figure 7. Removing harness wiring for bed lights.

Then you need to remove the two taillight plugs (see Figure 8 below). They are located at each corner of the back of the bed. Twist them and pull them out.

Figure 8. Remove tail light plugs.

Step 5 - Lift bed off the truck

This is where having a couple of buff buddies comes in handy. Each one of you should grab a side (as shown Figure 9 below) and lift the bed off the truck. If you don't have two strong friends available, you can always use bed hooks, two ropes, and a chain hoist to lift the bed. Once it is lifted, pull the truck forward and lower the bed onto a soft surface or several saw horses.

Figure 9. You and your super friends lifting the bed off your truck.

Step 6 - Locate and clean fuel pump module

Figure 10. Fuel tank with fuel tank module.

Whether you have removed the fuel tank (Option 1) or the truck bed (Option 2), the rest of this process is the same. For those of you who removed the truck bed, the fuel tank can be found just behind the cab. Looking down at the tank, you will find a round fuel pump module bolted onto the top. Before removing the six bolts, you will need to disconnect the fuel outlay and relay lines from the module. You will also need to remove the evaporative hoses. They are fastened by safety clips which you pull and release to free from the module. You can also use a 3/8" Ford Fuel Line Disconnect Tool for detaching hard-to-remove fuel lines. Only purchase the aluminium ones. The plastic ones are no good.

Then use a plastic brush to clean off the dust and dirt from the top of the module so it doesn't fall into the tank when you remove the module.

Pro Tip

Use a plastic brush when cleaning the module and tank. A metallic brush can produce sparks, which you want to avoid when working near your fuel tank.

Next you will take out your Sharpie pen and mark a spot on the module and the tank so you can align the new pump properly when installing it (See Figure 11 below). The idea here is to know the exact positioning of the old module in order to identically align the new one.

Figure 11. Marking your fuel tank for proper alignment.

Step 7 - Remove old fuel pump assembly

After making your mark, grab your 8mm wrench and remove the six bolts that attach the gas pump module to the tank. Twist and lift the unit out. There is a good chance it will be stuck to the rubber seal underneath and won't budge very easily. If that is the case, very carefully use a flathead screwdriver to pry it up. Then lift the assembly out of the tank (as seen in Figure 12 below).

Figure 12. Lifting fuel pump out of fuel tank.

You will see that the fuel pump module is composed of many parts, including the fuel pump, fuel sender, and strainer. If you are a seasoned mechanic and you know what specific part is not functioning properly, you may just want to replace one of the individual parts. But if the pump is old, it's advisable to just replace the entire unit with a brand new one (as shown in Figure 13 below).

Figure 13. Motorcraft Ford F-150 2004 Fuel Pump Assembly.

Step 8 - Install new fuel pump assembly

Now that the old unit is out, you will drop the new unit down into the fuel tank, aligning it to the mark you made with your Sharpie. Replace the screws and tighten it up. Reconnect your outlay and relay lines and your evaporative hoses.

Step 9 - Put your truck back together

This is pretty self-explanatory. If you took out the bed, you will need to reinstall it and reconnect your lights, gas fuel filler cap and neck clamp. If you took your tank out, that will need to go back in. Be sure to reconnect all straps and bolts, and reattach your fuel fill line.

And there you have it: A new fuel pump. And another mission accomplished. Now all you need is an endless highway and a sunset.

Figure 14. Ford F-150 drives off into the sunset (www.jimprishing.com).

How to Replace Fuel Pump

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