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How to replace the fuel pump       #: 2236
 Moderated by: NoPower, Mike69, MaDMaXX
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 Posted: Sat Aug 22nd, 2020 10:33 pm
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Mike69

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This "how to" was again performed on my 2000 Ranger Extd Cab. It was average difficulty, if you have mechanical know how, hand tools, floor jack & jack stands you can do this. 
The tools I needed were,
1/4" drive ratchet,
1/4" drive extension,
1/4" drive 9/32 socket,
1/4" drive 1/4" socket,
3/8" drive ratchet,
3/8" drive extension,
3/8" drive torx bit #- T55,
rubber mallet,
1" wide piece of wood about 1 foot long, or a long straight blade screwdriver,
wheel chock,
new plastic fuel line retainer clips, & fuel line spring clip retainer remover tool.

1) After putting a wheel chock in front of one of the front tires I jacked up the rear of the Ranger & put 2 jack stands under the rear axle & set it on the stands.
2) I removed the 3 screws from the filler neck & pushed it out of the opening in the bed side, removed the 6 torx bolts that secure the bed to the frame.
3) Unplugged the harness back at the rear bumper that goes to the tail lights.
4) With a helper I lifted one side of the bed & then the other side, & my helper (wife) slide a 2x4 under the the bed on the frame rail. Then at the back of the bed I again lifted the bed & my helper slide a short length of 4x4 under the bed on top of the 2x4 so the bottom of the rear of the bed would be above the rear bumper. You could also use an engine hoist to lift the bed off the frame as I have done in the past.
5) With your helper slide the bed back far enough to access the fuel lines, electrical connection, & the fuel pump assembly retainer ring.
6) Two of the fuel lines have the plastic retainer clips, & the third one has the spring retainer. Remove the 3 fuel lines, the electrical connection, & the plastic retainer ring & remove the fuel pump assembly.
7) Unplug the fuel pump electrical connection, loosen both fuel pump hose clamps, & remove the screw on the clamp the holds the fuel pump to the assembly, remove the clamp & the fuel pump.
:NOTE: The replacement Bosch fuel pump has a different connector on the top of the fuel pump then the original Ford pump but they supply a adapter wire that plugs into the Bosch pump & the wiring on your assembly plugs into the adapter wire so there is no wiring that is needed to be done, it is a simple plug & play replacement.
8) Install the new filter screen on your new pump, install the new fuel pump hose on the new pump, install & tighten the 2 hose clamps & install the pump. Install the fuel pump retainer clamp & tighten the retainer clamp screw. 
9) Reinstall the fuel pump assembly back into the tank with a new tank seal & screw on the retainer ring being careful not to cross thread it.
10) Reinstall the 3 fuel lines, hook up the electrical connection, & check to see if it starts.
11) If all is OK push the bed back into place & remove the two 4x4's & the two 2x4's.
12) Reinstall the 6 torx bolts using anti-seize on the bolt threads & align the bed & tighten the torx bolts, reinstall the filler neck back into the hole in the bed side & install the 3 retainer screws, & install the gas cap & you are done.



____________________
08 Escape 4x4(spare)
00 Ranger Extd Cab 4x4 4.0 OHV, Auto(My DD)
99 Explorer Sport 4x4 4.0 SOHC, Auto( Wife's DD)
69 Mustang Coupe 5.0, 5 spd(Project & my future toy)
14 Kawasaki Vulcan (Wife's Toy)
Splitting time between southern NJ & Southern Virginia.
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 Posted: Sun Aug 23rd, 2020 01:47 pm
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mhoward
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Nice write-up Mike!



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2003 Ranger Edge / Extended Cab / Flareside / 3.0L FLEX / Auto / 2WD / 8.8 Open 4:10 / Sonic Blue Pearl

So many mods... so little time...



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 Posted: Sun Aug 23rd, 2020 01:54 pm
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410customs

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very nice!
If you replace the entire in tank sender (the fuel level gauge and pressure regulator for 98+ dudes) it is a good idea to test the function of the level sender before you install the assembly into the tank, make sure when the float is at the bottom the gauge reads empty and when its at the top it reads full.
Also test your new fuel pump BEFORE you bolt the bed back down :)



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I build custom RBV, specializing in drivetrain conversions, wiring, suspension and complete custom trucks
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 Posted: Thu Sep 10th, 2020 08:40 pm
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Ranger_Danger_
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I wish I could've removed the bed over dropping the tank in my truck.

Being lifted, I was able to just crawl under, squeeze myself between exhaust and driveshaft to cut the fittings(I did not want to fuss with the fitting tool. And I was due for all new lines anyways).
I used a lift dirt bike stand to lower the tank into my lap. (After siphoning about 10 gallons out of my FULL TANK)

Smacked the crap out of the lock holding it in and replaced the whole pump. 

Be sure to also re-trip the inertia switch on the passenger side! Mine went "off" when I did the pump, so you have to press the red button to be flush. Or else the new pump will be useless. :)



____________________
"So Many Ideas. So Little Money."
"If You Ain't First, You're Last."
--
2007 Honda Accord 2.4L(New Daily)
2005 Ranger 2.3L 2WD XLT (My Baby)
2000 Explorer 5.0L 2WD Eddie Bauer (Donor)
2008 Yamaha YZ85(Toy)
2008 Honda CRF230L(2nd Toy)
2009 Chevy Aveo5 LS 1.6L
1998 Mustang GT 4.6L (Boyfriend's DD)
1991 F-150 SCLB 2WD 4.9 *Undergoing 5.0 Swap*(Spare)
1984 Mustang 2.3L (Boyfriend's Project)
1997 Honda Shadow 1100 Spirit (Boyfriend's Toy)
2009 Kawasaki KLR650(Boyfriend's 2nd Toy)
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 Posted: Thu Sep 10th, 2020 08:42 pm
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mhoward
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Interesting that changing the pump would kick out the fuel shutoff.  Nice bit of info to keep in mind... :-)



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2003 Ranger Edge / Extended Cab / Flareside / 3.0L FLEX / Auto / 2WD / 8.8 Open 4:10 / Sonic Blue Pearl

So many mods... so little time...



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 Posted: Fri Sep 11th, 2020 12:34 am
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It was 4 years back but I lifted the bed with my engine hoist and ratchet straps when I replaced the guts in the tank.  I wire brushed the frame and painted it with Rust-Oleum. Only surface rust but I probably saved the spare tire holder.  I also changed out the shocks and serviced the axle. I tried to do everything possible to the rear of truck while the bed was off. Shackles were good.  I even took measurements for a second fuel tank but did nothing with it.

I drove it for about a week while I was working on the frame. That 3.0 was burning the rear tires like I had a 427 wedged in up front. Interestingly I  went from 20 mpg to 24 mpg even doing the burnouts.



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 Posted: Fri Sep 11th, 2020 06:15 am
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Mike69

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Tony, the previous times when I removed the bed from my Ranger I used my engine hoist, I was offering another alternative because not everyone has one.



____________________
08 Escape 4x4(spare)
00 Ranger Extd Cab 4x4 4.0 OHV, Auto(My DD)
99 Explorer Sport 4x4 4.0 SOHC, Auto( Wife's DD)
69 Mustang Coupe 5.0, 5 spd(Project & my future toy)
14 Kawasaki Vulcan (Wife's Toy)
Splitting time between southern NJ & Southern Virginia.
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 Posted: Fri Sep 11th, 2020 12:52 pm
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mhoward
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@Tony: Does the bed weigh that much?



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-- Michael

2003 Ranger Edge / Extended Cab / Flareside / 3.0L FLEX / Auto / 2WD / 8.8 Open 4:10 / Sonic Blue Pearl

So many mods... so little time...



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 Posted: Fri Sep 11th, 2020 07:23 pm
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Ranger_Danger_
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mhoward wrote:
@Tony: Does the bed weigh that much?
Mine weighed a lot more because I had the camper shell on at the time. No longer have that on there. (Thank god. Ugly thing)



____________________
"So Many Ideas. So Little Money."
"If You Ain't First, You're Last."
--
2007 Honda Accord 2.4L(New Daily)
2005 Ranger 2.3L 2WD XLT (My Baby)
2000 Explorer 5.0L 2WD Eddie Bauer (Donor)
2008 Yamaha YZ85(Toy)
2008 Honda CRF230L(2nd Toy)
2009 Chevy Aveo5 LS 1.6L
1998 Mustang GT 4.6L (Boyfriend's DD)
1991 F-150 SCLB 2WD 4.9 *Undergoing 5.0 Swap*(Spare)
1984 Mustang 2.3L (Boyfriend's Project)
1997 Honda Shadow 1100 Spirit (Boyfriend's Toy)
2009 Kawasaki KLR650(Boyfriend's 2nd Toy)
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 Posted: Fri Sep 11th, 2020 10:25 pm
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Tsquare
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mhoward wrote:
@Tony: Does the bed weigh that much?
Not sure of the weight but my guess would be 325 plus or minus 50 pounds for the steppy. I was doing this by myself  and I removed the tailgate before I got started. This is also when I had those crappy Goodyear Wranglers. The 3.0 could turn them over about a half turn from a dead stop.



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Came out of retirement to drive a school bus - I have lost my mind
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 Posted: Sat Sep 12th, 2020 12:59 am
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mhoward
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I would venture to say the steppie is heavier.  The fiberglass sides would add up pretty quick.  I know the PowerDome hood is VERY heavy.



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-- Michael

2003 Ranger Edge / Extended Cab / Flareside / 3.0L FLEX / Auto / 2WD / 8.8 Open 4:10 / Sonic Blue Pearl

So many mods... so little time...



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 Posted: Sat Sep 12th, 2020 01:03 am
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Tsquare
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It was on the engine lift and when I put it back on all it took was a little nudge to get it back into place.



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Tony
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Came out of retirement to drive a school bus - I have lost my mind
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