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Old 01-17-2019, 03:12 PM   #1
RyanSwagMechanic
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Join Date: Jan 2019
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1999-2007 Ford F250 Fuel Pump Replacement

1999-2007 Ford F250 Fuel Pump Replacement
6.8L v10 gasoline engine

Tools:
13mm
x2 6in extensions
x2 jacks
Pliers
Flat Head Screw Driver
Pry Bar
Hammer
x4 Hose Clamps (Optional)

Problem:
Vehicle will turn over but not start.

Diagnosis:
If you follow the fuel rail on the passenger side back you will find a plastic cap. If you remove that cap you will see a valve. Take your flat head screw driver while the key is in the on position and press the valve. If fuel does not come out there is no fuel pressure. Open your fuse box and check the fuse and relay. (Fuse bottom left corner 3rd row up. Top left corner fuse Both 20A. Relay 3rd from the bottom)

Repair:
Raise the vehicle to desired height. Place a jack at each end of the tank. Taking your 13mm and two extensions take off the bracket bolts on the left hand side of the tank. Reaching above the tank remove your two fuel lines with the careful assistance of your flat head screwdriver. Unplug the connector to the fuel pump. Toward the front of the gas tank you will find one hose and hose clamp. Remove those from the tank. On the rear you will find two hoses and the fuel filler neck. Remove those. Carefully lower the jacks sequentially. Taking your pry bar and hammer place the pry bar on the circle screw on band atop the gas tank. You will see marks on the edge of the circle to place the pry bar. You then want to tap the back of the pry bar with a hammer to get the band to spin loose. Inside of the fuel tank you will see the fuel pump assembly that releases with two clips on top of the unit. Pay attention to how the assembly comes out as you remove it.

Assembly:
This is generally the same as taking it apart, when you put in the new unit the filter sock goes in first then place the unit where the two tabs will lock. Good practice will replace the gasket atop the tank because a worn gasket can lead to evap issues. Above listed was 4 hose clamps. You can replace the original pinch clamps for those hose clamps on the hoses and fuel filler neck for re assembly and that will cut some time out of the repair
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