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To replace the fuel pump you must remove the fuel tank form the car. You will need a floor jack and jack stands and then remove the steel straps that hold the tank in place and then the filler neck and drop down tank to access the fuel lines, disconnect the lines with the special tool kit and slowly drop the tank out.
Before servicing the vehicle, refer to the precautions in the beginning of this section.
Shift the vehicle into NEUTRAL and position it on a hoist.
Release the fuel pressure.
Disconnect the negative battery cable.
Remove the fuel tank filler cap.
Drain as much fuel from the tank as possible.
Using suitable hose pinching pliers, clamp the fuel tank filler hose.
Clamp the fuel tank filler hose in the location shown
Disconnect the three quick connect couplings from the fuel tank tubes at the tank.
Disconnect the fuel pump electrical connector.
Disconnect the fuel filter inlet tube from the filter.
Position a suitable lifting device under the fuel tank.
Remove the two fuel tank support strap bolts.
Lower the fuel tank to access the fuel pump module while swinging the fuel tank support straps away from the tank.
Clean the area around the fuel pump mounting flange.
Disconnect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
Using the special tool, turn the fuel pump module retaining ring counterclockwise and remove it.
CAUTION The fuel pump module must be handled carefully to avoid damage to the float arm, filter and convolute hoses.
Turn the fuel pump module counterclockwise and the fuel pump module will release from the locking tabs. Remove the fuel pump module from the fuel tank.
Install the fuel pump module in the fuel tank.
Connect the fuel pump module electrical connector and the fuel pump module fuel outlet tube.
Raise the tank into position and install the mounting strap bolts. Tighten the bolts to 26 ft-lbs (35 Nm).
Connect the fuel lines and electrical connectors at the fuel tank.
Lower the vehicle and refill the tank.
Connect the negative battery cable.
Turn the ignition key to the ON position to pressurize the fuel system.
The connectors tend to get dirt and debris in where the special tool slides in which prevents the little tabs from disengaging from the raised ring on the plastic pipe. Pull the line towards the pump as if you were trying to push it on even further and use compressed air to blow out any crud where the tool goes. Then insert the tool and push it in firmly while pulling the line toward the tool a bit to relieve the pressure on the little internal metal retaining clips and at that point with a little wiggling the line should come off. I've taken off dozens and they can be exasperating to say the least. IF all else fails and you are certain that you are going to replace the pump module and absolutely can not get the lines disconnected for the stubby plastic fittings on top of the old one then you could simply break off the plastic fittings on the old pump so you can work on getting the fittings disconnected once you have the tank out. I've had to do this a couple of times but it means that the old pump module can't be used again since the fittings would be broken off of it. Be extremely careful working around the tank as it will be full of gasoline fumes and extremely flammable!
DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.
FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE REPAIRING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.
Disconnect the battery.
Relieve the system pressure.
Raise the vehicle.
Drain the fuel tank.
Disconnect the fill pipe hoses.
Loosen fill pipe hose clamps.
Disconnect fill pipe hoses from the fuel tank.
Remove the 4 bolts (2 each side) and remove the skid plate if equipped.
Support the fuel tank.
Remove the bolts and pivot the fuel tank support straps away from the fuel tank.
Disconnect the vapor line fitting at the rear of the fuel tank.
Lower the fuel tank.
To install, reverse the removal procedure
Clean the area around the fuel pump mounting flange.
Using the special tool, remove the fuel tank pump assembly locking retainer ring.
Remove the fuel pump assembly. CAUTION: The fuel pump assembly must be removed and handled carefully to avoid damage to the float arm and filter.
Remove and discard the fuel pump mounting gasket.
Clean the fuel pump mounting flange and the fuel tank mounting surface.
Apply a light coat of Premium Long Life Grease XG-1-C or -K or equivalent meeting Ford specification ESA-M1C75-B to the gasket to hold it in position during assembly. Install the fuel pump mounting gasket.
Using the special tool, tighten the fuel pump assembly locking retainer ring.
There are two metal straps that hold the tank in the vehicle. First you will need to disconnect the filler neck from the tank and any other black vent hoses that will pose a problem. Place a floor jack under the fuel tank and remove 2 bolts (1 in each strap). Then carefully lower the tank. You will need a special tool for the actual fuel lines where they are connected to the pump. It is called a quick disconnect tool. Once the tank is free of the vehicle you will see the pump housing on top. Most likely has about 8-8mm bolts that will need removed-and there is your fuel pump.. Labor guide calls for 2hrs -normally takes about 45mins to complete..
this is for gas tank behind axle, not in front of axle.
SECTION 310-01A: Fuel Tank and Lines—Gasoline and Diesel
1999 Econoline Workshop Manual
REMOVAL AND INSTALLATION
Fuel Tank — Aft-of-Axle
Fuel Line Disconnect Tool 310-5039 (T90T-9550-5)
High-Lift Transmission Jack 014-00942 or equivalent Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before repairing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard. NOTE: The 55 gallon aft-of-axle fuel tank (9002) is shown; the 35 gallon aft-of-axle fuel tank is similar.
Disconnect the battery ground cable.
Relieve the fuel pressure; refer to Section 310-00A .
Drain the fuel from the fuel tank; refer to Section 310-00A .
Raise and support the vehicle; refer to Section 100-02 .
NOTE: In this illustration, the vehicle body is shown removed for clarity. Disconnect the fuel tank filler pipe (9034) and the filler vent tube from the fuel tank.
Position the jack under the fuel tank.
Remove the 3 bolts.
Remove the 3 nuts.
Remove the fuel tank support straps (9092).
Partially lower the fuel tank.
Disconnect the fuel lines from the fuel pump (9350); refer to Section 310-00A .
Disconnect the fuel pump and fuel tank sending unit electrical connector.
On gasoline fuel tanks, disconnect the hose(s) from the evaporative emission valve (9B593).
On gasoline fuel tanks only, disconnect the fuel tank pressure sensor electrical connector.
Lower the fuel tank.
If the fuel tank is being replaced, transfer the fuel pump, fuel tank sending unit, the evaporative emission valves and the fuel tank pressure sensor (gasoline fuel tanks) or the plug (diesel fuel tanks) to the new fuel tank.
WHAT YOU WILL NEED TO DO FIRST IS JACK THE TRUCK UP AS HIGH AS SAFELY POSSIBLE.. BE SURE TO USE JACK STANDS THAT WAY THE TRUCK DOENT FALL OVER.. ONCE UP IN THE AIR HE WILL NEED TO TAKE THE GAS TANK OUT OF THE TRUCK.. THERE ARE TWO STRIPS HOLDING THE TANK INTO PLACE..THEN WHEN HE GETS THE TANK ON THE GROUND, REMOVE ALL THE FUEL LINES.(THERE ARE CLIPS ON THE PLASTIC LINES BE EASY) THEN WHEN HE GETS THE LINES LOOSE, THERE IS A METAL RING ON THE TOP ON THE FUEL TANK..HE CAN USE A SCREW DRIVER TO GET THE RING OFF( HE WILL SEE HOW TO TAKE IT OFF WHEN HE LOOKS AT IT) WHEN THE RING IS OFF PULL THE FUEL PUMP ASSEMBLY OUT OF THE TANK AND REPLACE THE FUEL PUMP (THE WHOLE FUEL PUMP WILL JUST NEED PULLED OUT, NO SCREWS) ..JUST REPEAT THESE STEPS BACKWARDS TO REINSTALL .. THIS SHOULD SOLVE YOUR $700 PROBLEM..GOOD LUCK AND THANKS FOR USING FIXYA.COM...KEITH..
There is special disconnect tool just for 98-00 classic CK pickups. Lisle makes them they are a two piece plastic tool that is pretty cheap to buy. Do not buy a regular disconnect tool bcause they will not fit in the lines at the pump. The lisle number at Carquest is 37500. Please rate.
NO dont drop tank, you will be sorry, take bed off, only like 6 or 8 bolts, and you will have more room to work, and its a pain in the *** to undo the lines and drop the tank, you cant get in there to do it, but just basic tools nothing special, be sure and try not to make any sparks while takein off that ring to get the pump out, and put an ac delco pump on there