95 Transport - Okay, I need to change the fuel pump. Give it to me straight...

[yellowfiero]

How big a job is this?

Just want to assure myself that it is the fuel pump, I don't get the 'buzz' when I turn the ignition on. I disconnected the cable at the tank, and jumpered 12V and gnd directly to the connector on the tank side (grey / black wires) and no pump sound. So unless its something else, I'm darn well sure its the problem.

What's involved in this job?

[yellowfiero]

Okay, finished the job - it took about 1.5 hours total. Not bad at all!

Here are some highlights:

After searching for a replacement pump, I decided to go with a Bosch, since it had the only lifetime warranty. The OEM and basic replacement pumps only had 1 year warranties. The Bosch looked very well made (Brazil), not China.

I replaced the filter sock on the end of the pump too.

Since my bad pump was intermittent, I was lucky it was still working when I had the car in the garage. The gauge said 1/2 a tank, so I was looking at siphoning the rest of the gas out. Instead, I had a stroke of brilliance. Since the pump still worked, I hooked the pressure gauge to the test port on top of the engine. I removed the gauge side of the hose, and then extended the hose down to a gas can. Then I disconnected the fuel pump connector under the vehicle, and jumped power to it directly, so the pump ran without the car running. The pump then proceeded to pump the tank out by itself!!!!

That saved me big time!

Then I dropped the tank by myself, took the ring off and the whole sending unit came out.

Very similar to what this guy did:

http://www.autoblog.com/2006/08/03/a...el-pump-randr/

The Bosch dropped in without much issue. I had to redo the connector, because it was different than what was in the tank.

The problem, it turned out, was not the pump after all... The connector was melted at the pump, and was having a bad connection. Either way, the old pump was going in the trash, I feel much more secure with the Bosch. I was dismayed at the melted connector - what if it sparked when the tank was filled with air/gas???????

Anyhow, I wanted to reply to my own thread so that others searching in the future would be able to ascertain whether this job is one for them. I did it all entirely by myself with zero help. Hope this helps you, whoever you are that read this in the future!!!

[LMP]

Good work, Yelllow..and yes, that was a real risk issue.....after all, this is close to what they said blew TWA 800 from the sky!

[aamirmali]

Thanks for the info...