Fuel Pump Access Hatch

[linus69]

My 02 F150`s fuel pump decided it was time to retire after getting a fill up just prior to a snow storm when the temperature was 9degs and I had the snowplow mounted. I towed it home and went thru the diagnosis, fuses,relay and the inertia cut-off switch were all good and the engine showed no codes. I had been having occasional starting issues for a few weeks prior to the failure. It started and ran fine on starting fluid, I changed the fuel filter and while the outboard side of the filter was still open I cycled the key several times. Not a drop of fuel came out of the filter so I was pretty sure it was the pump.
I have the 8ft bed with the optional large fuel tank. After 12 years of rock salt winters it looked ugly to either drop the tank or remove the bed.
So I opted for the "redneck engineering" method of cutting an access hatch thru the bed. I did this with a pneumatic cut off tool using a thin 2 1/2in cutting disc, luckily there is plenty of clearance to the top of the tank. It took less than an hour to accomplish, I was taking it pretty slowly and when the hatch was created the old pump removal took less than 10mins.
I opted for a Carter replacement pump assembly because of their high ratings and 12 month warranty.I found one on ebay for $120 delivered, and had it in three days. Around here the same pump was $200plus so I didn`t mind the wait. It took less than 10mins to install the new Carter and hardly a drop of fuel was spilled. I then used aluminum bar stock to patch the panel back in with stainless steel zip screws.
With the new pump installed the truck runs better than it has in some time, plenty of power and my gas mileage has even improved.

















Paul

[Rich Waugh]

Nice job, Paul! Much more sensible than trying to drop the fuel tank. I hate these new in-tank fuel pumps, anyway.

[linus69]

Thanks Rich, in this case it was the only way to go as far as I`m concerned, Utube has been a very good and helpful resource.

[Rich Waugh]

While there's a raft on pure garbage on YouTube and the entire 'net, there is certainly an equally large volume of real valuable information. I find the 'net to be a tremendous resource. Just as you have found.

I think you definitely made the right decision on your fuel pump problem and executed it well. I like to see that sort of thinking. I remember thirty or forty years ago funninginto a problem with changing the plugs on a Corvette. The recommended method was to loosen the motor mounts and lift the entire engine to get clearance to access the rearmost plugs. What nonsense! I cut a hole in the fender well and got the plug out in two minutes. I made a nice cover for the hole that could be used again and again. Simple and cheap!

Today's automotive engineers only seem to be concerned with meeting the goals set by the weasels in the accounting department and screw the customer and the mechanics who have to deal with the problem later. So we have fuel pumps that require removing an entire truck bed or fuel tank to access, suspension parts that require excessive disassembly to replace, oil pumps that require removing the engine to drop the oil pan (my '85 Chevy S-10) because it would have cost another five bucks to make a frame crossmember removable, and so on. The only saving grace in all this is that today's cars go a lot longer before needing most of these things done, and only produce 1/10 of the pollution of cars from before about 1995. If they could pay some attention to after sale maintenance, I'd think real progress had been made. Okay, I'll get down off the soapbox now. (grin)

Glad you got the problem solved in a sensible and efficient way!

[linus69]

Well said Rich, a factory provided hatch over these in-tank fuel pumps would be the way to go. But I`m afraid it`s all about "planned obsolescence" now, and the dealer makes a very nice profit from after sale maintenance and repairs. For replacing this pump the lowest Ford quote was $1100, highest was $1600. With a hatch in place the pump changeover takes less than 30mins to accomplish and was a lot safer than dealing with the removal of 32gals of fuel.

[ronj]

How did you determine where to make the cut-out and how large, etc.? You did it so accurately.

[linus69]

I did it (the measuring) from below with a hand held mirror and a tape measure, I also had a sideways cross member/brace to contend with that I did not want to cut through so I cut along it`s edge using the factory spot welds as a reference point from above. I then used blue painters masking tape and a sharpie to create the outline and followed that line and also checked my cut from below a few times during the process. I don`t think I would consider changing one of these pumps on any older rock salt and road-brine exposed vehicles any other way. Turned a potential nightmare job into a pleasure.


Paul