How to Replace the Fuel Pump on a 2002 F-150

The fuel pump and sending unit on a 2002 Ford F-150 are combined into an assembly that is best replaced as a single unit. The unit is mounted within the truck's fuel tank, meaning you must remove the tank to access the fuel pump. The fuel system is under a great deal of pressure, so use caution and check with your mechanic before you begin working on it.

Things You'll Need

• Jack
• Jack stands
• Flat-head screwdriver
• Block of wood
• Wrench
• Marker
• flare-nut wrench
• Acetone/lacquer thinner

Instructions

Removing the Fuel Tank

1. Relieve the fuel pressure by unplugging the inertia switch connector--located behind the passenger's-side kick panel--and running the engine until it stalls.

2. Disconnect the truck's negative battery cable.

3. Raise the truck's rear end and support it on jack stands.

4. Disconnect the filler and vapor hoses from the tank by loosening their clamps, disconnect the fuel and EVAP lines at their quick-connect fittings and disconnect the electrical connectors. Use a flat-head screwdriver.

5. Raise a floor jack under the tank to support it, placing a block of wood on the jack head to protect the tank.

6. Unbolt the tank straps with a wrench and swing them away from the tank.

7. Lower the floor jack with the tank on it, and remove the tank.

Replacing the Pump

1. Highlight the alignment markings scribed on the fuel tank and the fuel pump assembly, using a marker or paint.

2. Remove the six mounting bolts from the fuel pump assembly--a flare-nut wrench works best--and remove the pump assembly from the tank.

3. Clean the fuel tank's mounting surface and seal ring groove with acetone or lacquer thinner.

4. Install the replacement fuel pump assembly with a new seal ring into the tank. Carefully angle the unit into the tank without damaging the strainer, and make sure the alignment marks line up. Then apply the bolts.

5. Raise the fuel tank back into place and bolt the straps back on. Connect all fuel lines, hoses and electrical connectors with their clamps or quick-connect fittings, then lower the truck.

References

• "Chilton Ford Pick-ups Repair Manual"; Eric Mihalyi; Haynes North America; 2003