2002 Ford F-150: Replacing the Fuel Pump

This video documents the process to replace a fuel pump in a 2002 Ford F-150. Please note there are some minor variations based on wheelbase. These instructions can also be widely applied to most Ford vehicles as the process is similar for most.

[@SweetWillie5150]

Thank you. Thank you. Thank you. Great video, I broke down last week and got towed, diagnosed, and was told it would cost me 735.00 to replace my fuel pump on my truck. I still had to pay 125.00 for the tow and diagnostic, but I looked at your video and purchased my own pump for 175.00 (total of $300) saved myself $435.00.

[@emziraliz3317]

I decided to remove the truck bed on my 2001 F250 to replace the fuel pump since I didn't want to spend all that time laying on my back. Using five 8 ft 4 x 4's and several 2 x 4"s for cross bracing I constructed a frame over the bed of the truck, removed the 8 bolts holding the bed down disconnected two electrical connectors and using a chain fall lifted the bed up. Then I pushed the truck forward. About 15 minutes later I was lowering the bed back down onto the truck. It took longer for me to construct the lifting frame than it did to remove the bed and install the new fuel pump. Not bad for an 80 year young man.

[@AllPurposeAtheist]

I could do that, but I'd have to hire a Uhaul to get all my crap out of the shop first. The driveway's on a hill so that idea's out..

[@cliftt]

A younger man might buy a six pack and get 3 friends/neighbors to help lift.

[@calforman]

Easier to Just Cut a Window access, to the Fuel Pump area.. and Seal it with a new Plate ...than you have access... I cut an H to bend the Edges,..

[@groth3395]

@@calforman i always wondered why the manufacturer didn't do that (removable access plate)...seems like an easy thing to have done to truck beds...granted sometimes the truck frame sometimes covers the fuel pump access. BUT, that too could be engineered out. That assumes of course the manufacturer gave a rats ass about its consumers woes

[@garyt7830]

@@groth3395 I drew Lines Measured very well,, Cut an H so then Both Pieces I bent left and right ... took a Grinder, and made sure I didnt go all the way through, to keep sparks at a minimum ... I also just in case through a blanket soaked with water, on the tank for Insurance. but a shear Cutter will work better ... I made the Opening,,, wha La It was right on top of the Fuel Pump... Then after i replaced the Fuel Pump,, I simply closed things back , and put additional Plate for insurance ,, It was a ton easier than removing a Fuel Tank .

[@troybond5426]

Thank you for sharing. I’m fixing to half to replace the Full pump & hanger assembly tomorrow. I’m thankful I found your video of how to do this on a 2002 F-150. Looks like a job

[@jarana8277]

I must confess, I'm a fool! I found the problem. I had forgotten to remove the protective cap from that line and it had jammed into the fuel line. I was able to reinstall the lines after I pulled that out. Truck fired right up. Thanks again for the great video.

[@ElChapitofz]

My dad got the tank off his 2002 f 150 before he passed away so i now have to put a new pump and put it back on, i want to get it running and fix it right in his memory

[@Pony-Corral]

I just replaced the fuel pump on my 1968 Mustang. Piece of cake. Glad I watched this before trying to replace pump on my 2002 Lariat. Not even in the same food group. Thank you for doing this video.

[@bill756239]

I just looked at lowering the tank as you described vs raising the bed and decided to raise the bed instead and it was easy. Now I have great access to the pump

[@TheyMightBeRacing]

Great! I believe that if I have to ever do a similar job again I will always check to see which option is easier.

[@glen432003]

My hats off to you dude , I’ve gotta replace mine on my 99 , but after watching this I think I’ll remove the bed ! Lol

[@AllPurposeAtheist]

Remember the good ol days when you could just slap an inline fuel pump just about anywhere near the tank? That used to be my go-to method, but I guess those days are over.

[@sirjordanpowers]

PB Blaster can loosen the nastiest bolts, I love the stuff.

[@Cowcharge]

A tie-down strap hooked to the frame at each end of the tank and running alongside the tank straps works great for hanging and lowering the tank.

[@richardwelch3706]

Great job!! It sure makes it easier when someone can put it in simple steps. Thanks!!

[@wayneflemmer2607]

Well after watching this I'm cutting an access door in the bed of the truck way easier than all this. Takes about 20 minutes and you are right there. Unbolt it take it out no breaking things put the new one in and that's it.

[@jamesspano2335]

Were you able to get to the fuel pump by cutting the bed if so can you send me a picture.

[@hitman62968]

Definitely want to take your time on hoses, removing bed is easist, especially chevrolet. Ford uses torx bolts from top down. An 01 ,such as mine get pretty rusted. At the shop its all good, but at home they can be a pain. Even lubing, heating, and breaker bar can turn out bad. Even at shop , after braking loose thay can snap your socket, t47 or t50 or worse strip the torx bolt.I use the new snapon 1/2 impact with snapon tools. Your way is good if you cant get the bed bolts out.Only thing I would do to add would be to take 5 min to remove drive shaft. You can sit up under truck as the tanks lowered and reach lines alot easier. All in all good video tho.Rock on.

[@Sandman368]

Great video, very informative. I do recommend that you wear safety glasses when you are working on anything that poses an eye hazard threat!

[@davidgillenwaters8712]

Even with a crew cab or a Supercrew, removing the bed helps. It's much easier to get to the connections on the top of the tank. It's 6 bolts, a clamp that holds the filler neck to a tab on the bed, 3 screws that hold the filler neck to the body, the main plug for the light harness, and the tag lights. It sounds like a lot but it really isn't. I removed the tailgate (slips right off) and my daughter's boyfriend and I lifted it off. Great video though. Thanks.

[@kujawat]

very true... much easier with the bed free..

[@TyroneSteeledrumatlanta]

With my f150 5.4 crewcab 4x4 2001, removing the bed helps. However, still need to drop the tank to get to the pump assembly. It's under the cab.

[@mikeschmidt7145]

Tyrone Steele Tyrone, that is the same truck I have. what led you to think it was the Fuel Pump? Mine does this surging thing at an idle, sometimes it will surge up to 1700RPM and then down to 300RPM. Sometimes just a couple hundred RPM. I have replaced the Idle control box already. Just purchased truck so don't know much about history.

[@davidgillenwaters8712]

Mike- have you checked for trouble codes? That sounds like an intermittent vacuum leak.

[@TheyMightBeRacing]

Raising the bed is an alternative method. It has it's own set of challenges, but many claim it's easier.

[@JoseDominguez-gf7xk]

Great video It helps a lot just in the part when you put the new pump you forget to install the new seal at least that you installed before you finish the video

[@mrhhj]

Thank you for the knowledge. Great video.

[@tommills9753]

Great video. I'll be doing my 1999 for f150 tank.

[@michaeljones1410]

Great video, appreciate the effort and time you spent creating and sharing.

[@MarkAntney]

Great, great, DIY Video. I see why it's an expensive job. So much so, I might take it to the shop but the video clearly showed (though time consuming) if you're mechanically inclined; you can do it.

[@twirlyboggs]

great great post ! my wife just filled the tank yesterday. Go buy 4 lawnmower tanks to add to my 1 and start siphoning. I ALSO may pull the REAR TIRE to help. Those connections can be not so bad to cussing so loud my neighbors want to call the law bad

[@jaymann49]

Thank You So Much You Just Saved Me A Lot Of Time !!

[@FireDoug2001]

Jody, Great video walk through. I just ordered my fuel pump for my f250 and going to be completing this in a week. Your video was very helpful.

[@billymitchell4045]

Thank you, you helped me a lot.

[@darcyfoster5982]

Just pull the 6 50 torx bolts off thr bed and move the box back 3 ft. The whole operation to mo e the box off is about ten minutes and you can do everything from above.

[@Melonate248]

Thanks dude!! This video was a great help! And whats funny is Im pretty sure that you live in my neighborhood lol

[@TheyMightBeRacing]

Possibly. If you drive by a house with a big black F-150 and a driveway full of British cars, then it's likely me.

[@martysaskatchewan740]

Heat shield? ?? Its a frickin skid plate.

[@trivigonzales]

Not bad replaced it in 21 minutes 👍🏽

[@thomas4315]

Knew my van needed to be done. Seen a traveler tuber with a Astro van got stuck with a full tank on a scenic Look out . Saying it could not be worst. But he somehow change it cause he had the pump in case. So I cut my van small 6 “ square and fold it up. I was going to change it but the stupid metal out letlst needed a ac tool plyer type. The tool store was junk. So had the van tow to ford made appointment got there 4 hr late. The kind manager cut me in line of company’s vans. Owner not there. Becuse I had the parts and the hole cut. They did it 15 minutes and said no charge. Not kidding. Felt sorry because I live in it. Very grateful there. Would have been big bucks

[@rbk7876]

Protective Eyewear is a must !

[@tasmaniandevil7610]

Ant spray as well haha

[@115mfd]

UPDATE, the tool does NOT work on the fuel lines at the fuel pump. NO tool needed. After 2 hours and steam coming from my ears I cut the lines to get the tank out. The ends on the lines have a plastic keeper that you can release with your fingers. Mine were not color coded, both were black. The clamps on the other hoses were of the compression type and not the screw type. I have pictures to show if needed. 2002 F150 Lariat, FX4 Crew cab, 5.4L

[@jordankv]

Definitely worth it to remove the drive shaft and ratchet straps made raising the half full tank back in place fairly easy.

[@su5119]

Seemed to be a good video. Didn't see you putting a gasket down before the new pump assembly?

[@cliftt]

Gasket is attached. He noted that the old gasket was part of the old unit.

[@TheJSmithBA]

What about hoisting the bed off and replacing the pump that way? Or maybe cut out & construct an access hatch. Either way thanks for sharing. Cool vid.

[@johnkerr8019]

I hope you enjoyed a few beers after that job, it looks to me like you earned them. I was considering completing this task on a ford fiesta Mk 5 (UK), but may pass it to the mechanic. it looks like a 5 spanner job. (LOL)

[@alpinehs]

Great video

[@groth3395]

watching this has convinced me NOT to attempt this job. You are a experienced and had one issue after another that you have to overcome.

[@k9sarnj]

Great info, Ty for doing this video.

[@nikkiengland9673]

Removing the bed wont work on a crew cab. Fuel pump is under back seat.

[@kujawat]

very true, the Supercrew tank has to come out.. .but I've found just lifting the bed a bit makes disconnecting and reconnecting the hoses and lines easier by doing it from the top.. i found out because the first supercrew i went to do, i didn't realize the pump was under the cab... so while i had the bed loose, i finished up the job.. can't say it was much quicker.. but for the 10 or so minutes it takes to free the bed.. it makes it alot easier..

[@davidgillenwaters8712]

kujawat Pulling the bed off was the easiest part of the job. Those $#%& "quick release" fuel line fittings were a pain though.

[@dannypalmer7701]

Yep those hose clamps you cannot reach they at the top.That makes it hard to get off.Struggle and wiggle!! ect.

[@GeraltOfRivia99]

wouldnt it be easier to siphon out the gas out of the tank? might make things a hell of alot lighter with a hose pump. then after yyour done add back the gas

[@1guyin10]

I agree. Those vent lines are a pain.

[@graveyardrumblers]

Shield?... My 98 don't got no shield 😆... Should I be concerned?

[@dannypalmer7701]

yep small hands can help alot.also a second helper.

[@dannypalmer7701]

Some days are terrible even if you a good experienced !

[@abeeftec]

How far can you drop that tank before it starts destroying Wires and connections?

[@MrRemo58]

I just cut an access hole in the bed , took five minutes

[@antoniotorres3000]

I think on a four door the fuel pump is under the cab.

[@MrRemo58]

@@antoniotorres3000 you're correct

[@bobjohnson8206]

I could never understand why Ford still have tank straps where they could have designed it to be bolted to the frame. Ford could have designed an inspection cover plate into the floor board so you could reach the lines and electrical connectors from on top to remove and install them. These engineers aren't to swift a total crappy design and they leave it that way for years never improve it. Nice video though, thanks for posting it.

[@alexgordonepic]

i just got my tank out. yeah those fuel line connections were tough.. i dettached all the evap hoses and lowered the tank about 3 inches to make the fuel lines easier to detach -those were the hardest for me before i lowered the tank.. my left hand kept cramping up.. I'm gonna try to hook up fuel pump to 12v in the morn. and check it before putting the tank back in. is that possible?

[@tskipwadoo3447]

I had a 2002 Avalanche, it cost me $1200 to get a new fuel pump installed at the dealership. It hurt !

[@sirsweetness8332]

I hired a lovely assistant also on many car repairs. 🤪

[@johnoverstreet708]

Sir Sweetness mhnnhnhu

[@katdvjackson]

Your video was well made! Verry descriptive and the visuals were spot on. My question is do you have one showing replacing a fuel pump in a 2009 F350? I can't find one on You Tube.

[@TheyMightBeRacing]

To disconnect said wires and connections? Somewhere around 4-5"

[@Pastor_of_Muppets]

Much easier to remove the bed... easier access, quite a bit faster, no need to remove the fuel from the tank.

[@dannypalmer7701]

Some days can be bad and things can go badly wrong!!-

[@eduardolejarazu350]

Thank you very good help your video

[@PetPeePee]

Thank you so mach you are very good Thank you

[@johniec2]

Would it be easier to lift the bed instead?

[@scottfiocchi596]

That is not a heat shield.

[@eltecladistademetlatonoc1]

No pusiste gascket

[@JROC734]

I own both Ford and Chevy vehicles, and there's some things on Fords that are generally easier to work on than the same part on a GM, and there's some things on a GM that's generally easier to work on than the equivalent part on a Ford. One thing that is way easier to do on a GM vehicle is to get the damn fuel lines to let go. GM fuel lines are easy to get off where Ford lines are a PITA in my experience.

[@jodykerr60]

Yep, I've worked on all sorts of vehicles over the years. When it comes to fuel lines I have to say that Studebaker takes the cake. Double Bubble flares on steel lines and quite often all lines need to be made from scratch because there are no N.O.S. parts for them. Getting a good seal on a double bubble is an art and skill that I absolutely suck at.

[@garycrawford6539]

Thank you. I don't have jack stands, or an impact wrench, or a long extension, so I am going to take it somewhere to get fixed. Hate to part with the money, but my ability and time are a factor too.

[@dannypalmer7701]

Id be cussing!! 😆 Wife says quit cussing!! 😆

[@goheat77]

08:28 Mom the neighbor is talking by himself again...

[@dannypalmer7701]

Dang dirt will fall in your eyes.

[@billyhensley592]

That's not a heat shield that's a skid plate that came on four wheel drive models

[@jb1995]

thanks for the info!

[@jamesspano2335]

Is your truck a SuperCrew with four doors?

[@rigobertocano2782]

Thanks

[@jcharro]

Thanks for the info..

[@antoniodecarlo6915]

I need to replace my fuel pump on a 2001 F250 Super Duty with a full size bed & a 38 gallon tank, Is it easier to remove the bed than drop the tank and if so has any one had experience doing so? How heavy would the bed be? Antonio

[@morgan5941]

8 bolts was all we removed from my brother's bed. Having 3 or 4 people handy makes lifting and blocking go easier. The actual fuel pump replacement took 10 mins after that.

[@scottphillips4992]

It's a whole lot easier to take the bed off.

[@jamesspano2335]

Is it possible to cut a hole in the bed please reply

[@jaymann49]

Will not bleeding the fuel line not make the gas gage work ? Or did I set the pump not properly?

[@TheyMightBeRacing]

The fuel gauge is read from the fuel sender on the tank. It's one of the electrical connections on the top of the tank. If your gauge is no longer reading, then the connector wasn't reconnected properly. Or, there's something wrong with the sender.

[@iyanaharris5039]

How to instole the key lock in a Mercury Marques 201

[@TheDbell]

you twist all those connections off of the fuel tank. Do not have to remove the rubber hoses

[@jarana8277]

This video is great. Any chance you have an email I can reach out to? I encountered some difficulty reattaching the fuel lines to the fuel pump. To be more accurate the blue pressure line. It doesn't seem to fit. I noticed on your video you had some difficulty getting them back on. What did you end up doing? No problem attaching the grey one.

[@TheyMightBeRacing]

J Arana Look us up on Facebook.

[@JH-qz3gh]

I have a 1989 250 custom gas where do think I can get a fuel pump from it from?

[@ki11er42]

good video except you could've just removed the bed.. that's what I did

[@dannypalmer7701]

It can pop back off

[@emziraliz3317]

The comment below under Emzi Raliz was written by Me, Antonio DeCarlo. After I Posted it Emzi Ramiz"s name popped up as the poster and I have absolutely no idea how that happened.

[@stevewheatley243]

Those Ford quick disconnects aint so quick sometimes. Not after they been there for yrs.

[@KiTTeNChaoSS]

Ethanol gas destroy the fuel pump? Is there a replacement ethanol compatible replacement pump?

[@Theymightbehomesteading]

On a modern vehicle like the 2002 F-150 Ethanol shouldn't be an issue as the cars are designed to deal with it. The place where ethanol can cause trouble is on older cars. For example we have a lot of problems with vintage cars and ethanol.

[@KiTTeNChaoSS]

Locally (CAN, Victoria, BC) we have had two of our fleet vehicles having fuel delivery problems 2007 Ford E150 & E350?. The Ford dealership service dept said all of a sudden in the last 3-4 weeks they've had to replace 100 pumps, well above the average few they do a per year. Something is up.

[@TheyMightBeRacing]

KiTTeNChaoSS Thanks for the heads up. I wonder if Ford changed suppliers and got some made with cheap rubber.

[@KiTTeNChaoSS]

Apparently it's not just Ford vehicles. Hearing about 1 motorbike, 1 Japanese car, 1 Chev Blazer, in my circle of friends locally. I wonder if they are sneaking it into the fuel to keep the costs down, due to the NATO/Ukranian/Russian issues putting pressure on fuel costs?

[@Tom-ic7hw]

I think I'll just use my angle grinder with a cutoff wheel and make an access hole in the bed my truck isn't that nice plus I got slide in bed liner to hide the hole

[@robmcraf2765]

I am going to have to do this to a stock 2002 F150 in the near future. Last time i changed a fuel pump is was 15 years ago on a Cadillac Cinnebun. Is there any advantage to taking the bed off vice dropping the tank? The bed has a plastic bedliner so those fasteners wouldn't be easily accessible. Probably just go with dropping the tank.

[@TheyMightBeRacing]

You'll have to evaluate that for yourself. I've had a bugger of a time when I've had to remove my bedliner, so I prefer to avoid doing it if at all possible.

[@johnking1079]

I'm doing this now on my 2001.... It's no problem removing the bedliner or the bed... just remove the rear tie-downs and the liner pops out. The pain is actually removing the bolts holding down the bed. You'll likely have to cut them off or drill them out (~$40 on Amazon to replace). I3 weren't too bad but the remainder wouldn't budge with impact wrench, propane torch and PB blaster I had to cut them out with an angle grinder Would be easier next time... My preference for removing the bed was...1. I don't have to have the tank lowered over me to remove it... 2. It's actually a good opportunity to examine the frame for rust and handle appropriately. One caution if you have a Super Crew like I do... the pump is actually under the CAB, so I have to remove the tank.... My mistake, but I found some rust I wan't to address, so no problem.

[@dannypalmer7701]

No gasket,?

[@happyjack8952]

The one thing I wanted to see, you do not show, nor even explain. Lines and hoses ??

[@TommyT777]

The fuel pump for my 97 F-150 is $548 retail up in Canada. Luckily I got it for $300 + tax on account. Are they really $100 in the US?

[@yruhatin100]

Actually I just got mine for $11.99 on ebay. The whole fuel unit starts at $46 but the fuel pump itself is dirt cheap. Regardless of price, all these pumps are likely made at the same Chinese factory. BTW removing the truck bed is the best and fastest way to get to the fuel pump.

Ignore the above reply - I got mine (get a Bosch or Delphi unless you want to be doing this AGAIN soon... this advice was from a REAL Mechanic) mine is a Bosch from Napa (2000 F150) for $107.91 for pump and for strainer ... keep in mind the 100 buck ones are the pump ONLY - not the whole unit

[@jodykerr60]

seker7 I also prefer to buy the complete units. It is possible to do the job more inexpensively by buying just the pump. but as you point out, caveat emptor. May the buyer beware.

[@yruhatin100]

Jody Kerr Apparently you guys don't understand the world of marketing hype. In this day and age of outsourcing for max cost cutting and max profit, everything is likely made in the same Chinese factory but with different logos for different OEM and sold at very different price. I bet you seker7, "REAL mechanic" thinks that he is just as good as the dealership, right? I have replaced only pumps in two separate cars without performance issues. If I have any issues, I will update this tread. It's your money, feel free to do whatever you want.

[@jodykerr60]

yruhatin100 I simply buy the best quality part with the best warranty coverage possible.

[@BluesFactor]

I always suggest smoking a cigarette at some point

[@DoctorRickSanchez]

wow

[@graveyardrumblers]

I did that a bunch of times just diagnosing the problem.

[@MegaThunder70]

That is one bad a.. Truck

[@rugby3874]

Safety glasses.

[@TheyMightBeRacing]

Even with the gas removed from the tank it is still really heavy.

[@AllPurposeAtheist]

I have to pull mine soon and just filled it before the fuel pump crapped out..On the other hand it could be a completely different issue. Occasionally getting old and being able to pay someone else has its advantages.. I might just do that this time around.

[@cliftt]

@@AllPurposeAtheist What did u do?

[@KimboDogg07]

You really should brake those bolts first by hand then put the impact on it... Just saying

[@BUGSR]

where is this located looks like N. Phoenix, AZ my old neighborhood lol cactus / bell area

[@TheyMightBeRacing]

+David R. It was filmed in Tempe. So, not too far away.

[@javiereduardojimenezflores6386]

BUGS R.

[@kchilz32]

+TheyMightBeRacing I see you are a Sox fan. Are you a fellow New Englander?

[@SilverBullet93GT]

13:58 that's what she said

[@unhinkable29]

Tells you not to force the tank strap, and then throws it right after saying it XD

[@johntiberia6885]

I can't believe your under there with all the dirt and shit falling down on you that you didn't get anything in your eyes with no safety glasses on.

[@powertvau]

Impact driver not impact wenche.. That's a fuel tank guard