2003 F150 Fuel Pump Replacement

[N80]

I need help with a problem. I have a 2003 Ford F150 that probably has a dead fuel pump. This is basically a farm truck and stays down at my cabin so there is no urgency to fix it.

I have watched all the videos about how to replace the fuel pump. Even though it requires removing the bed on most models I feel like I could do it myself if that was all that was involved. Unfortunately mine is the 4 door (super crew) and the fuel tank extends up under the cab. So the only way to get to the pump is to drop the fuel tank. Without a lift I am not up for that job. The videos I've watched of people dropping the tank without the truck being on a lift often do not go well.

Just wondering if any one else has done this job (on a 4 door) and if you have any advice.

The other thing I am considering is removing the bed anyway hoping that that would improve access to the tank and allow me to put straps underneath it and such as that.

Any advice much appreciated. And yes, I could have someone else do it but that's going to involve winching it onto my trailer and hoping someone at the mechanic shop can help me to push it off the trailer and into the right spot. That would take time away from work which is just mo money down the drain for an old beater farm truck.

 

[Slowpoke Slim]

Just wondering if you're certain it's the fuel pump, and not just the shutoff solenoid?

 

[N80]

I checked and it is not the fuel pump fuse. It could be the fuel pump relay which I am going to replace. I'm going to replace the fuel filter as well. I'll do both of those things before diving in. The emergency fuel pump shutoff was not tripped.

 

[LittleBill21]

if its a farm truck? why not cut through the floor in the cab?

 

[TractorGuy]

I haven't done it but if and when I do I would put the truck up on jack stands and lower the tank with a floor jack. I have done my Mustang like that. Wasn't a lot of fun but wasn't impossible.

My 2003 F150 has had difficulty starting when hot for several years. I suspect the fuel pump check valve is letting the pressure bleed off but it always starts by the third try so I've been putting it off. It fires right up when it's cold or if it's just been shut off for a minute.

Not sure how the truck pump differs but when I did the mustang most parts places wanted to sell the whole tank assembly with the fuel sender and all. I found just a pump at O'Reilly for much less.

Also to note on my Mustang I had let it sit a while and I'm pretty sure the ethanol ate up the pump armature. When I changed the filter and dumped the inlet side out in a pan it was slam full of rust. The tank was spotless inside and the protective coating was intact. The only other place the rust could have come from was the pump.

 

[Alan W.]

Its not as hard as you think. Recently changed out the gas tank on the church van that a vandal punched a hole in to steal gas. Put a new fuel pump in while it was out.
Drain all the fuel and they aren’t that heavy. A bit cumbersome. This was a 38 gallon steel tank. I think yours maybe plastic. Make sure and soak the saddle bolts with penetrating oil. I had to replace the ones on the van due to corrosion they twisted off.

 

[N80]

@LittleBill21 I've heard people do that with the truck bed but not the cab. However, I'm willing to poke around in there and see what that would involve. I don't weld so not sure how I'd seal it back up.

The tank on this truck is only 25 gallons but it is at least 5 feet long and has a 1/4 tank of gas in it. It is steel and not plastic. Also has a skid plate under it. From what I've been able to gather it is hard to get the gas out because of an anti-siphon valve somewhere. Not sure about that though.

Putting it on jack stands is an option but I still would prefer not doing all the work from under the truck. I'm not old but I'm not 20 either. Back and neck give me fits working under a vehicle.

I do appreciate all the advice and it is all probably more sound than what I'm contemplating. My wife wants me to take it to a shop and have someone else do it. That may be the best advice but I sure hate to drop that kind of money on an old farm truck.

 

[brokeasajoke]

Does this truck have a fuel pump driver module? Can't remember which models did.If so those tend to give trouble as well.

 

[N80]

I'm not sure. The 04 and up seem to but I looked for one where they are on the 04 and could not find it.

I've watched a few more videos and have decided the job is not for me. Going to take it to the mechanic at some point.

 

[N80]

Changed my mind again. Going to replace relay and fuel filter. If still no go I'm going to pull the bed off if it doesn't fight back too hard. If it still looks too hard with the bed off I'll take it to the dealer with it off. From all the videos the only real hard part about bed removal is the bed bolts being seized. Then it looks like a nightmare. Mine look okay from up top and underneath and I'll soak them with break-free for a day or so.

 

[Alan W.]

Just remembered that the 04 year of 150 had a fuel module located next to the spare tire and they were known to go bad or is this what you are calling the relay.
Usually you can tell they are bad by looking at them due to the corrosion.

 

[N80]

I could not find such a module on my 03, at least not anywhere near where it is on the 04. None of the 03 and earlier diagnostic work ups have mentioned that module. So not sure if there is one on the 03. Anyway, once the bed is off I track down anything and everything connected to the fuel system. The fuel pump relay switch is in the fuse box. It was like $3 on line so I have one on the way along with a fuel filter and fuel line disconnect tool.

Have had a hard time finding a 1/2" drive T50 torx impact drive for removing the bed. Lots of people break the standard (non impact) ones. None of the local stores including auto parts stores, Northern Tool, Harbor Freight have one in stock locally. I hate (HATE!) Amazon and Chinese tools but I ordered one. Not sure it will be any stronger or better than a non impact one. We'll see.

 

[LittleBill21]

I could not find such a module on my 03, at least not anywhere near where it is on the 04. None of the 03 and earlier diagnostic work ups have mentioned that module. So not sure if there is one on the 03. Anyway, once the bed is off I track down anything and everything connected to the fuel system. The fuel pump relay switch is in the fuse box. It was like $3 on line so I have one on the way along with a fuel filter and fuel line disconnect tool.

Have had a hard time finding a 1/2" drive T50 torx impact drive for removing the bed. Lots of people break the standard (non impact) ones. None of the local stores including auto parts stores, Northern Tool, Harbor Freight have one in stock locally. I hate (HATE!) Amazon and Chinese tools but I ordered one. Not sure it will be any stronger or better than a non impact one. We'll see.

I strongly recommend you buy this. I use to break bolts constantly with my impact, this has been over 80% successful if you can get the air tool in there. it provides a shock to the entire bolt and not just the head.

https://www.amazon.com/Mayhew-37315-8-Inch-Pneumatic-Breaker/dp/B008M23A5U?dchild=1&keywords=shake+and+break&qid=1620703561&sr=8-7&linkCode=ll1&tag=ast45-20&linkId=a6648d081102c82f35fbae45e60d1cb7&language=en_US&ref_=as_li_ss_tl

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[brokeasajoke]

I could not find such a module on my 03, at least not anywhere near where it is on the 04. None of the 03 and earlier diagnostic work ups have mentioned that module. So not sure if there is one on the 03. Anyway, once the bed is off I track down anything and everything connected to the fuel system. The fuel pump relay switch is in the fuse box. It was like $3 on line so I have one on the way along with a fuel filter and fuel line disconnect tool.

Have had a hard time finding a 1/2" drive T50 torx impact drive for removing the bed. Lots of people break the standard (non impact) ones. None of the local stores including auto parts stores, Northern Tool, Harbor Freight have one in stock locally. I hate (HATE!) Amazon and Chinese tools but I ordered one. Not sure it will be any stronger or better than a non impact one. We'll see.

It just hit me, yours probably does not have a driver module. 03 was last year of Trition truck and that was a change introduced to the 04 model.

 

[Alan W.]

Same here. I was thinking it was an 04 not an 03.
I think the modules started with the 04 year.

 

[N80]

I got off work at noon today and headed down to the cabin. Got the bed off the truck in well under an hour. If the bed bolts are not rusted/frozen it is simple. One bolt was a little tough but PB Blaster loosened it up in no time. Used the FEL to lift it off the truck. With a tractor the size of mine and me being the only hand I would not recommend this approach for a nice looking daily driver. As is, my bed is already beat up and scratched up so it was no big deal.

I am glad I took this approach because getting the skid plate off and loosening the tank straps was much easier working from above and made getting PB Blaster on the bolts easier.

Getting the fuel lines off was still a miserable experience. They have little plastic clips (not the kind that there is a tool for) and the connection was under the cab in the frame rail. Could barely get my hands in there. Couldn't see. That alone probably took 30 minutes. I probably could have loosened the tank straps and made some more room which is what I should have done. I just couldn't tell how much play the lines had in them.

After that I just put cribbing under the tank and loosened the tank straps. The tank was about 1/3 full and plenty heavy but manageable with the cribbing. I just slid one piece of cribbing out at a time alternating ends until it was on the ground.

At this point the bed is off and tank all the way out. The whole thing, including clean up and getting the gas out of the tank (no small feat) took less than 3 hours. I don't think that was all that bad single handed.

Glad I took the bed off. That part was easy and made access to most everything much easier than working entirely under the truck. I'm too old for that.

Will buy the whole pump/sending unit and come down next weekend to put it all back together.

If it doesn't work after that I'm pushing it over a cliff.

 

[N80]

A general fuel system question. Does the fuel system need to be bled when all of this gets put back together? If so, how? I know there is a little valve on the fuel rail over the injectors.

 

[Alan W.]

I never had to bleed one that I replaced the fuel pump on. They arent like a diesel. May take a couple of cranks but she will purge the air snd fire up.

 

[N80]

Thanks!

Here are a few pictures of this adventure

 

[Alan W.]

Cant understand why fuel pumps cant be mounted on the frame rails and accessible.