Powerstroke fuel pump replacement tragedy?

[tallyho8]

After having a slow diesel drip in my beloved 1995 F250 powerstroke that I keep in mint condition, I determined that the chances are 99% that it is leaking out the weep hole in the fuel pump and decided to change it. The dealership wanted $1025 to change it and I was able to get all the parts for about $140 so I decided to do it myself.

The pump is in an extremely crowded area in the valley of the powerstroke where you can't even see it without a lot of trouble. I found good instructions on line and went and bought all the parts I needed ahead of time.

I followed the instructions and everything seemed to be going perfect when I finally started pulling up on the pump very hard to remove it from the valley. I thought I was pulling it straight up but must had pulled it sideways a little because the bottom of the pump broke off flush with the valley and remained stuck in it while I removed the pump. (see first photo)

When I saw what had happened I immediately had visions of drilling and ez-outs and metal filings going in my crankcase or a multi-thousand dollar repair job. (See second photo) I lost control and yelled a few choice words and caught myself just before I threw a hammer through the windshield.

After I calmed down I realized that it might not be as bad as I thought. First, I turned the engine over to see if the cam would push it out. No movement. Then I realized that the outer ring was a rubber o-ring and I got my snap-on pick and was able to remove it. Then I was able to push the outer part down a little so that the tappet shaft stuck up a little where I could get a small vice grip on it and pull up and remove everything. (photo3)

I was so thrilled that a calamity had been averted that I decided to have a couple of adult beverages and quit for the day and unwind. Everything is out now and so tomorrow I will have the whole day to see if I can put it back together again. Wish me luck!

 

[dave1949]

Good save! From the 'valley of despair' to joy, all in one afternoon Good luck on finishing it up tomorrow.
Dave.

 

[Bill_C]

Now go to powerstrokenation or thedieselstop and read up on converting to an electric fuel system. It's easier and cheaper than most people think, and it sure beats the mechanical system!

 

[tallyho8]

I finished my fuel pump installation today and was very relieved that there are no fuel leaks now. This is a very intimidating job for someone who is not used to working on diesels but the good instructions that I got at the dieselstop forum convinced me to go ahead and do it myself.

This is one job where it is really a huge help to have small hands and long fingers as it is such a tight fit.

 

[riptides]

Sweet job. Nice save.

Powerstrokes RULE. :^)

 

[AlanB]

Great job Tally, I thought I was the only one that did that kind of stuff.

Glad you got it fixed.

 

[tallyho8]

It occurred to me that I forgot to post a photo of my old 1995 F250 to show you why I want to keep this one as long as possible.

 

[czechsonofagun]

Great story, I love happy endings. Expecially the part about saving the day and quitting - that takes a lot of strength. Lot of people would have an adult beverage and mess with it again and FUBAR it totally.

 

[riptides]

It occurred to me that I forgot to post a photo of my old 1995 F250 to show you why I want to keep this one as long as possible.

Something to be said about older vehicles, they LOOK better. They stand out, have more distinctive features, and well....ahhh my opinion.

Very nice. I'd have gone to a dealer to save it, big hands and no brain on my part.

 

[Travelover]

Great story. I think that anyone that has done some serious wrenching has a experience with a little part diving into the bowels of an engine or other complex assembly. One side of you hopes against hope that the little part will sit in the sump forever and the other side knows it will end up destroying the whole engine.

 

[Egon]

Glad all turned out well.

For me I usually get to the broke stage and it's quickly downhill from there!

 

[SkyPup]

I absolutely hate it when these simple little 20 minute mechanic jobs turn in to 20 hours of frustration!!!

Glad to hear you were able to take care of it quick and effectively.

 

[Egon]

I absolutely hate it when these simple little 20 minute mechanic jobs turn in to 20 hours of frustration!!!

Uhh, did I tell you about when "She Who Must Be Obeyed" went to change a burned out light bulb on the front porch?

 

[Skyco]

Wow, haven't heard of that happening, but LOTS of people have dropped the little pushrod into the engine internals...
Hardest part when I changed the fuel pump on my 96 was getting that dang big fine thread banjo bolt on the back started back in without cross threading it...

 

[Just Dave]

I'm about to do the same job. My Fuel filter canister had two pin hole leaks of which I fixed thanks to Mr.JB Weld. Can you tell me what kind of wrench did you used to undo the banjo bolt behind the fuel pump without removing the turbo bracket.Thanks Just Dave

 

[Just Dave]

Oh Yeah, Will Natural Lite work when I break Something?

 

[tallyho8]

I'm about to do the same job. My Fuel filter canister had two pin hole leaks of which I fixed thanks to Mr.JB Weld. Can you tell me what kind of wrench did you used to undo the banjo bolt behind the fuel pump without removing the turbo bracket.Thanks Just Dave

The photo is the wrench I used to undo the banjo bolt. A 3/8 drive air ratchet with a short flex extension and socket and adapter.

 

[driver444]

I too am about to tackle this job on my '96. Except, I don't have a drip. I have ALOT of fuel pouring down my bell housing when the truck's running. And being a 5-speed, I could do without my clutch getting wet. Other than the fuel line itself being bad, I suppose it's gotta be the pump.

This has been an awesome thread.

 

[Bison]

The photo is the wrench I used to undo the banjo bolt. A 3/8 drive air ratchet with a short flex extension and socket and adapter.

One would do dickall with that itty bitty air ratchet on the one i did last year.Took a big *** combi wrench to crack that bolt loose.
I wouldn't wanna own one of these 7.3 contraptions if the gave it to me,what a PITA to work on

 

[Skyco]

I too am about to tackle this job on my '96. Except, I don't have a drip. I have ALOT of fuel pouring down my bell housing when the truck's running. And being a 5-speed, I could do without my clutch getting wet. Other than the fuel line itself being bad, I suppose it's gotta be the pump.

This has been an awesome thread.

There are other possibilities....I just replaced the filter restriction sensor on my 96 because it was leaking.
Another possibility is the filter canister itself sometimes corrodes through when people don't drain the water often enough. It is a very expensive part.

I just replaced my pump for the second time a month ago...my hands stilll haven't completely healed up from all the scratches and gouges. I'm almost to 200,000 miles. OEM pump leaked at around 80,000, its replacement made it to 195,000 and fortunately it had a lifetime warranty from Autozone...sadly they don't do that anymore, guess they found out some people keep a diesel pickup a long time.