Bed cutout for pump replacement

[sherman69]

Hi,
Yesterday I dropped the fuel tank for the pump replacement. Last time I lifted the bed because the tank was almost full. This time it was only a quarter full.
While my fuel tank is out waiting for the new pump, I plan to cut an opening so it will be easier next time especially if on the road.
I didn't do it while the tank was still in because there isn't a lot of clearance to the top of the tank and the fuel lines etc.
I have been measuring and figuring where to cut.
Does anyone have measuring suggestions?
Also I figure to get a piece of bed from a wreck bigger than the opening to cover it.
At least the tool box will completely hide the cut.

Bob B

[MT-2500]

Why chop up or butcher the bed up?
Beds are not made to cut up.
Fix it right with a good fuel pump to start with.
MT-2500

[Cadillakin'98]

I'm wondering the same thing as MT-2500, why create all this work for something that should really never be an issue (or atleast not a frequent issue)?

First of all, I think pulling the bed off is ALOT easier than dropping the tank regardless of how much fuel it has in it. I mean really, what are we talking about- 8 bolts to hold the bed on and 2 or 3 for the fuel fill spout?? It's a matter of approx 1 to 1.5 hrs for R&I even w/out air tools.

2nd, your fuel pump should not go out that easily. The reason why they go out is either because the vehicle constantly runs with little or no fuel which in turn burns up the pump as it is not designed to run dry. Similar to a garbage disposal in your house. If you run it dry, it will burn up.

So the easiest solution I would think is to keep atleast 1/8 of a tank at all times in your tank. I understand gas prices are rediculous. However, think about that $300+ it's costing you everytime you replace that pump.............

[Cadillakin'98]

Also, screw the lifetime warranty pumps your local parts store will try to sell you. Nothing beats the original brand that was specifically engineered for that particular vehicle. All aftermarket brands must be altered by about 20% to not be sued for copyright infrigment.....

[MT-2500]

10-4 on that Cadillakin'98
Fix it right to start with and take care of it and your problems on fuel pump is over with.
MT-2500

[sherman69]

Originally Posted by MT-2500

Why chop up or butcher the bed up?
Beds are not made to cut up.
Fix it right with a good fuel pump to start with.
MT-2500

--------------------------------------------------------------
Hi,
This is the third pump in 3 years.
The first died on the interstate while pulling my fifth wheel trailer.Needed a tow and because the extended warrantee company went out of business, I also needed $350.00 to pay the shop.
They used a Carter (which used to be a good quality brand) from NAPA. I never let the tank get below 1/4. It started acting up intermittantly failing to start a year and a half later, so I bought a pressure gauge to catch the problem. Then it failed on the road again. No trailer again just two passengers and a load of luggage to get to the airport.
This time I had a 120 mile tow to home and lifted the bed because the tank was almost full and I didn't want to have it fall off the jack.
I replaced it with a Delphi which is now the factory supplier. (They apparently own AC Delco). I had NAPA get it for me since I have a relationship locally with them, and they list it on their website.
I then took apart the Carter for a post mortem, and found the pump totally clean and free after removing it from the motor. But the motor was melted at the armature and brushes area and frozen up.
Never below 1/4 tank either.
Now this latest pump still under the one year warrantee is failing to hold pressure. It pumps good but the check valve is failing.
SOooo, I want to be able to replace the pump when on the road, and my bed is more work than some to lift because there are the 8 bolts plus 8 more that hold the fifth wheel hitch to the frame which needs to be re aligned when reinstalling it. Also the wires for the hitch have been added inside the bed on the wall and the wires aren't long enough to slide the bed back much.
I also don't want to cut the bed, but don't see any other option.
Bob B

[MT-2500]

Well if you you have to you have to do it.
You have had a lot of bad luck on the fuel pump.
One good replacement pump usually takes care of the problem. Make sure the wiring is all good.
A factory Oem pump might give you better service.
Sometimes oem only hurts one time.
Good Luck
MT-2500

[GMMerlin]

Causes of fuel pump failures that are over looked are clogged fuel filters, poor quality gasoline and loose connections or bad grounds.
The problem may not be the pump.

[sherman69]

Originally Posted by MT-2500

Well if you you have to you have to do it.
You have had a lot of bad luck on the fuel pump.
One good replacement pump usually takes care of the problem. Make sure the wiring is all good.
A factory Oem pump might give you better service.
Sometimes oem only hurts one time.
Good Luck
MT-2500

--------------------------------------------------------
When I put in the Delphi, Which is now the OEM (even though I think you can still get AC Delco). I also replaced the pump wiring harness which is recommended by at least one company and is in stock at NAPA.

BTW, I have a friend with a 97 Tahoe who had fuel pump problems and would hit the bottom of the tank which seemed to help get it running again.
The pump was replaced and of course it failed again on the road in the middle of nowhere Nevada. We were travelling in a two truck convoy. It was replaced again even though I told the mechanic it was only 3 months old, so please look close at the wiring.
They replaced the pump for a lot of money, His Tahoe uses the modular pump so you replace the whole thing 350 plus labor.
Needless to say, in the middle of the Aridzona desert, It wouldn't start even after hitting the tank this time. So we dropped the nearly full tank with several blocks and a small bottle jack.
We got it down almost to the ground and I was able to reach in and pull the wiring plug. I could bring it out to the wheel and look into it.
My language would make some blush after I saw the burned contact in it. We thought about it for a while and I went looking under the hood for a replacement pin (actually a female connection).
First thought was to rob one from a horn, but noticed the hood light was way more accessable, So we cut four inches off and replaced the burned one in the fule pump wiring. The pump was still practically new and it's pins weren't burned yet.
Later while at the counter of NAPA, I saw a large bulletin on the wall all about failing fuel pumps (obviously a common problem) and on the sheet was a picture of a burned contact. The picture could have been taken of the Tahoe.
Bob B

[GMMerlin]

I saw a large bulletin on the wall all about failing fuel pumps (obviously a common problem) and on the sheet was a picture of a burned contact.

hummm..imagine that

[sherman69]

Originally Posted by GMMerlin

hummm..imagine that

Well it was the mechanic that time not me or my friend.
We both requested the mechanic to look closely at the wiring and connectors.
In my case I'm using another Delphi pump which is said to be the factory part supplier now, and they own AC DELCO.
If I have any more problems, I will look for AC DELCO maye new old stock or a dealer parts network.
The original owner went 100,000 miles with no pump failures.
Bob B

[MT-2500]

You can not trust a certain brand to be the same OEM type pump that your truck calls for.
All of the major brands sell there brands on a cheaper line of parts for discount and major brand parts places.
A lot of parts co. will put in a order for a few thousand parts with a major brand but have them made up to there own specs.
Tire companys do the same thing. Go to wallmart and sears or other discount tire places and buy a major brand of tire. It may have a major brand on it but it is a cheaper line made up for the discount place.
In other words brand do not mean anything anymore.
You usually get what you pay for.
Go OEM factory parts for quality. OEM only hurts one time.
MT-2500

[sherman69]

[quote=MT-2500]You can not trust a certain brand to be the same OEM type pump that your truck calls for.
All of the major brands sell there brands on a cheaper line of parts for discount and major brand parts places.
A lot of parts co. will put in a order for a few thousand parts with a major brand but have them made up to there own specs.
-----------------------------------------------------------
Yes I saw that with Coleman ice chests at Kmart years ago.
I understand what you said about the brand company making lesser quality parts for the discount stores.
I asked for opinions when I was replacing the Carter from the road trip, and don't remember getting much like what you said.
I wanted original equipment and found Delphi was now it.
This time it was warrantee so I went for it.
If it goes again, I will search out a Delco pump.
BTW I finally got in touch with the original owner of my truck, he said the original pump was still on the trunk nearing 100k when I bought it.
Not back together yet, so no feedback yet.
I will get the tank back in today though.
Then go look closer at the coolant drip. While the upper manifold is off, so some of the work is done to remove the lower manifold.
Bob B

[Bob B]

Originally Posted by GMMerlin

Causes of fuel pump failures that are over looked are clogged fuel filters, poor quality gasoline and loose connections or bad grounds.
The problem may not be the pump.

Thanks,These suggestions are very good, but all have been looked at. New filter and pump sock filter each time, and new wiring harness the previous time. Post mortem of previous pump showed clean and free pump, but melted motor on the pump. After never running less than 1/4 tank. Grounds good (no rust California truck) but cleaned the area where the grounds go to frame.
BTW, Delphi is the factory part now, And that is what I used.
The upper manifold has AC and GM molded in, but also a lable with scan info that clearly says Delphi. This is on the original 1997 part.

Bob B (was Sherman69)

[Bob B]

Hi,
(97 K1500 5.7 truck.)
Well I put the truck back together yesterday. All went well. (I took my time and was slow because I have my wife's car to drive and also my old 1969 Land Rover named Sherman).
The fuel pump fixed the pressure leakdown, I left the new fuel pressure regulator in, and I replaced the manifold gaskets to fix the coolant drip that started up about the same time.
I've cut the opening in the bed and made a temporary cover using the piece I cut out and some plates on the edges. It drops right in, But I plan to make a real cover from a junkyard part. The local selfserve will take $10.00 for a piece of bed floor, but I haven't figured out how to cut it out yet.
Even got the distributor back in with my marks and have no error codes.
And wonders! no left over parts. There sure are a lot of sensors and wiring and brackets on the manifold.
I had one question when I got done about a little hose to nowhere on a solenoid for the fume vapor cannister (forgot its name). So I looked at a friends 97 Tahoe and it had the same hose to nowhere. So I figure it is a venting opening.
It smelled a bit rich at first, but the computer had to do a relearn.
No drips and it runs fine.

Bob B (was Sherman69)