F-150 Fuel Pump Replacement
How to Replace the Fuel Pump in a F-150
Fuel pumps wear out over time, whether it's an electric fuel pump such as the one found on this 2002 F-150, or a mechanical fuel pump found on older vehicles. With Ford Modular engines (4.6L/5.4L), a weak fuel pump can cause hard starts, rough idling, and even leave your vehicle stranded. Our local Ford dealership wanted over $800 to perform this operation (parts + labor). We replaced the fuel pump in about 3 hours for just over $300.
Wrench/socket set, T50 Torx driver, chain hoist or similar, silicon grease.
Time to Complete:
2 - 4 hours w/ 2 people
2002 Ford F-150
Dropping Tank vs. Removing Bed for Fuel Pump Removal
There are 2 methods for accessing the fuel pump; dropping the tank or removing the bed. Since we had the resources, we opted to remove the bed instead of remove the fuel tank. This eliminates risk of breaking a tank strap and spilling fuel. Additionally, removing the bed is a relatively easy 2 man operation, and we'd much rather work from above than below. If your bed bolts are corroded or you don't have the required tools necessary to lift the bed, you should consider dropping the tank.
F150 Bed Removal
The bed is secured by 6 T50 Torx bolts. Remove your bed liner (if applicable) and remove the 6 bolts. Our pickup had locking tabs on the bed bolts, so there was no need to have someone holding the nuts beneath the truck. Next, disconnect the wiring for the tail lights and the license plate lights. The plugs are located beneath the truck in the rear and exact location may vary based on your model year (trace the wiring to find the plugs). Also remove the fuel tank cap and the strap that secures the filler neck to the bed. Use your bed hooks, 2 straps/ropes, and a chain hoist to lift the bed. Pull the truck forward and lower the bed onto saw horses (if you want unlimited work space) or set the bed about 18" from the cab (this will provide ample room to complete the procedure, as the fuel pump is located directly behind the cab).
Fuel Pump Replacement Procedures
• Disconnect the negative battery cable to reduce the risk of arcing around the gas fumes.
• Assuming the bed or tank is already removed from the vehicle, disconnect the electrical connector from the fuel pump. Next remove the 2 fuel lines from the fuel pump (a flathead screwdrive may come in handy if the clips don't cooperate).
• Locate the arrow on the top of the fuel pump assembly. Highlight it with a marker, and then draw an arrow on the fuel tank so that you can properly install the new fuel pump in the correct location (the replacement pump will also have an arrow on it).
• Remove the 6 hex bolts that secure the fuel pump assembly to the fuel tank.
• Carefully remove the fuel pump assembly and old gasket. A flathead screwdriver may be used if the gasket is sticking. Do not allow debri to fall into the exposed fuel tank.
• Install the gasket and fuel pump assembly opposite removal. A light coating of silicon lubricant can be applied to the new gasket to ensure a positive seal. Make sure the arrows on the fuel pump and tank line up, then reinstall the mounting bolts.
• Connect the fuel lines to the new fuel pump assembly, and then the electrical connection. Reconnect the negative battery cable.
• Reinstall the bed or tank and test the new fuel pump. It's normal for the truck to turn over more than usual during this first start as air is being purged from the fuel line. We recommend cycling the keys several times for 10-20 seconds at a time.
F150 Fuel Pump Replacement Photos
(click to view fullsize)