Fuel pump easy replacement

This is my first post, so I thought I'd contribute with meaningful content :)

This is a really great idea:

So most suburbans (GMC/Cheverolet) have a problem with the fuel pump. It's speculative as to what exactly causes the fuel pumps to go bad so quickly, although after reading the message boards, I've come accross heat/length of wire/bad design problems.

My fuel pump went out at 108k miles (tonight). My neighbor is a service manager at a local dealership, who happenned to know a master tech who works for Chevy. The Master Tech came out to my house. With him, he had an aftermarket fuel pump (worth $350), which he sold me for $50.

Rather than drop the gas tank to get the the fuel pump, we came up with an ingenious (some might call it ridiculous) solution. We lifted the carpet in the back of the burb. Then we carefully drilled a pilot hole right above the fuel pump. We then cut a square above the fuel pump.
We accomplished this using a 4 inch disc/ryobi saw. This was able to cut through the 2-3 layers of sheet metal, without touching the lines.

We then peeled back the sheet metal, and to our surprise, an exact guestimate of the location of the fuel pump. We then disconnected the high pressure lines, and removed the fuel pump from the tank. Replaced the fuel pump, and popped the assembly back in. Reattached the lines. Before we buttoned up, we started the truck. BINGO.

To clean things up:

Fold back the steel flap, so it is flush with the floor. Cut a piece of sheet metal (larger than the square you first cut), to go over the flap. We then used tape under the sheet metal, and screwed the sheet metal into the steel body. It mounted pretty flush. For extra pre-caution, we need to silicone the surroundings of the sheet metal, such that we have no air leaks. Then fold the carpet back down over the sheet metal. YOU CAN'T Tell. Yes it sounds hokey, however it works extremely well. Now whenever I have a fuel pump go out, I can easily remove the cover, and get to the fuel pump in about 5 minutes.

If done right, you really aren't going to hurt anything. You have to be willing to say to yourself, "I have an older car, It's mine, I'm not selling it, etc".

The total process took about 2.5 hours, as oppossed to 4-5 hours it may take, if you choose to drop the tank.

Also, It cost me only 200 bux out of pocket rather than 700. Food for thought.

Next 40,000 miles it will only cost me the cost of the fuel pump :) Grin.

This is my first post, so I thought I'd contribute with meaningful content :)

This is a really great idea:

So most suburbans (GMC/Cheverolet) have a problem with the fuel pump. It's speculative as to what exactly causes the fuel pumps to go bad so quickly, although after reading the message boards, I've come accross heat/length of wire/bad design problems.

My fuel pump went out at 108k miles (tonight). My neighbor is a service manager at a local dealership, who happenned to know a master tech who works for Chevy. The Master Tech came out to my house. With him, he had an aftermarket fuel pump (worth $350), which he sold me for $50.

Rather than drop the gas tank to get the the fuel pump, we came up with an ingenious (some might call it ridiculous) solution. We lifted the carpet in the back of the burb. Then we carefully drilled a pilot hole right above the fuel pump. We then cut a square above the fuel pump.
We accomplished this using a 4 inch disc/ryobi saw. This was able to cut through the 2-3 layers of sheet metal, without touching the lines.

We then peeled back the sheet metal, and to our surprise, an exact guestimate of the location of the fuel pump. We then disconnected the high pressure lines, and removed the fuel pump from the tank. Replaced the fuel pump, and popped the assembly back in. Reattached the lines. Before we buttoned up, we started the truck. BINGO.

To clean things up:

Fold back the steel flap, so it is flush with the floor. Cut a piece of sheet metal (larger than the square you first cut), to go over the flap. We then used tape under the sheet metal, and screwed the sheet metal into the steel body. It mounted pretty flush. For extra pre-caution, we need to silicone the surroundings of the sheet metal, such that we have no air leaks. Then fold the carpet back down over the sheet metal. YOU CAN'T Tell. Yes it sounds hokey, however it works extremely well. Now whenever I have a fuel pump go out, I can easily remove the cover, and get to the fuel pump in about 5 minutes.

If done right, you really aren't going to hurt anything. You have to be willing to say to yourself, "I have an older car, It's mine, I'm not selling it, etc".

The total process took about 2.5 hours, as oppossed to 4-5 hours it may take, if you choose to drop the tank.

Also, It cost me only 200 bux out of pocket rather than 700. Food for thought.

Next 40,000 miles it will only cost me the cost of the fuel pump :) Grin.


Good idea for a DIY...what scares me is that these guys are probally doing this on customers cars in the shop..and charging you full price.

ok heeis another idea me and my brother came up with we did the same thing only we took a gas filler door from junk yard truck drilled to holes in the floor for mounting and put a rubber gasket around it the old door has a lock on it so all that you do is put the key in and open the door see ya

?? Cutting a hole in the floor is easier?? I've put 3 pumps in my ' burb before gmmerlin told me what the culprit was. (the positive wire to the pump in the sending unit assembly) I dropped the tank each time. The first time took me 2.5 hrs. The last time took me and hour and 5 minutes!

I thought of doin that same kinda thing last weekend when me and my buddys dropped the tank in my yukon to change the fuel pump... well if i ever have to do it again thats what im doin...

the old jeep wagoners had a door in the passenger compartment for just this purpose, smart thinking on there part.

99 Burb 76000 mi, pump hums real loud, and my gauge stopped working. It is doomed?