Fuel Pump Nightmare

[E83]

Noticed a steady fuel leak from our 94 b4000 plow/yard truck a few weeks back. Finally got around to lifting the bed this weekend. Two days, four torx bits and an angle grinder later, I got the bed up.

Turns out that the metal "tube" that run out of the fuel pump assembly had rusted through on the feed line, causing fuel to stream out when running.

Since this is a pos yard truck that won't ever see a paved road again, I was hoping to pull the fuel pump, bypass the rusted out tube connector on top of the assembly and run a fuel line directly in to the housing and down to the pump, securing it with hose clamps and then using a fuel tank epoxy to seal around where the line runs into the housing. I am thinking this will work since based on photos of the pump assembly, there is already a rubber line running from the actual pump up to the metal tube at the top of the housing.

Of course, nothing is easy. Pulling the wiring harness resulted in it crumbling in my hand - will need to get a new one of those now... But even when I got the harness disconected, I couldnt for the life of me get the white plastic retaining ring on top of the assembly to unscrew. I tapped it, with a flathead and nothing.

So - even if I do install a new fuel pump assembly, it seems the old one is stuck in there anyway. Any suggestions on how to get this ring to budge? The amount of rust and corrosion around it suggests to me that a new assembly is needed anyway - but either way I have to get the old one removed.

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[RonD]

Welcome to TRS

Use a 1x2, 2x4 or piece of plywood instead of metal screw driver to tap on the fins, and go around to each fin tapping until it comes unscrewed.

Wood is better than metal because it doesn't "dig in" to the plastic, with metal, especially pointed metal like screwdriver or chisel, most of the "tap" goes into deforming the plastic not moving it, no so with the wood.

Strap and chain wrenches often won't help because they actually clamp the plastic ring on tighter when they "grip it"

Last resort is to cut it off, by hand, no electric tools on gas tanks, especially empty ones
And rinsing it out with soap and water if possible is also a good idea, via filler tube, if tank is out

 

[E83]

Thx. Will try this next. Any thoughts on connecting a fuel line directly to the pump? The nipples on top of the sending unit for the feed line rusted off. Was thinking I could drill it out, feed some fuel line directly through the top of the assembly casing and hosenclamp it on to the pump - then drop it back in and connect the fuel line from the pump to the line on the truck with a coupler and some hose clamps.

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[Spott]

Your fuel line proposal sounds like it would work, however at this point it might be advisable to replace the entire pump/sender assembly.

If the fuel tube has rusted through, the plate that supports the entire assembly is probably in similar condition, and will either not survive the disassembly, or will fail in the near future.

A new assembly will include a new pump, fuel level sender, bracket and tubing, and electrical connector, all as one part.

 

[E83]

Pounded the hell out of it using a short length of 2x4 as suggested - darn thing still wouldnt budge.

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[E83]

Been soaking it in wd40 for three days since I started at this. Any other suggestions? I imagine this ring which costs no more than 59 cents to manufacture costs 49 dollars at a parts store... So i dont want to cut it / destroy it... Despite how tempting that is at this point.

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[RonD]

They cost 61 cents to make

LMC truck has them for $14-$25
Wrecking yard may have similar one, common size on Fords

 

[55trucker]

check Rockauto for both an inexpensive complete pump & the lock ring..

 

[E83]

Finally got the pos off. A week later.

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