How to Replace a Fuel Pump in a Ford F-Series

The fuel pump in a Ford F-Series is electric so you should check the fuses and relays before inspecting the fuel pump itself. If you have fuel in your tank but your vehicle has difficulty getting fuel, you may need to clean your fuel pump or replace it entirely. The Ford F-Series comes in a variety of styles and this may affect your choice of fuel pump.

Instructions

1

Determine the fuel pump that your Ford F-Series will require. This depends on the make and model and engine size of your vehicle. Each generation of the Ford F-Series trucks features a range of engine sizes. Those made before 1966 generally have six-cylinder engines in the 200 to 300 cubic inch (ci) range.

2

Look at the development of the V8 engine in F-Series trucks. A 352 ci V8 engine was introduced in 1966 and V8 engines quickly increased in size, reaching their peak in the 460 ci engine introduced in 1973 that was available until 1979.

3

Examine the effect of the fuel crisis on the engine size in F-Series trucks. Engines from 1980 on were much smaller but gradually increased in power. The latest generation debuted in 2004 and is available in 4.2 L, 4.6 L and 5.4 L sizes.

4

Disconnect the negative battery cable with a socket wrench and relieve the fuel system pressure. Drain the fuel from the tank and remove the skid plates. Disconnect the fuel tank filler hoses and connections for the front fuel tank. Remove the evaporative emissions hose clamp and hose from the rear fuel tank. Unplug the fuel pump's electrical connection.

5

Support the fuel tank with a jack, remove the fuel tank straps with a socket wrench and remove the fuel tank. Remove the fuel pump bolts if you have a metal tank or the fuel pump retaining ring if you have a plastic tank. Remove the fuel pump by squeezing the fuel pump's retaining ring and discard the O-ring or gasket.

6

Install the new fuel pump using the items included in the kit, especially the O-ring or gasket.

7

Complete the installation by reversing the removal procedure. Tighten the mounting nuts for the fuel pump to 80 to 107 in. lbs. with a torque wrench if you have a metal fuel tank. Use a torque wrench to tighten the fuel tank strap bolts and skid plate bolts with the required force, which varies by model and year.