F-53 Fuel Pump Change Pictures

[IRON WORM]

I dropped the 75 gallon tank on my 96 Coachmen Santara and changed that troublesome fuel pump before it stranded me somewhere. I did the job alone and it was a bear, but worth the peace of mind. Here are the pictures.
Jeff

[LVJ58]

Great post, on "DIY" step by step "How To" excellent pictures.

Thanks,

[Clifftall]

[QUOTE=IRON WORM;705355]I dropped the 75 gallon tank on my 96 Coachmen Santara and changed that troublesome fuel pump before it stranded me somewhere. I did the job alone and it was a bear, but worth the peace of mind. Here are the pictures.
JeffAttachment 5538

I agree great job

AND

[tderonne]

Very similar to my '04 V10 75 gallon tank. Different strap under the tank, but similar concept, take them out. Also on the newer tank, there studs for the sending unit instead of bolts. Mine were a bit rusty, one even snapped as I backed the nut off. Luckily there was enough of it left to put it back together. Something to watch out for if you're doing a newer tank.

I drove the rear wheels onto some boards to give myself a little more room underneath.

(Didn't have to replace my pump. I revised the venting for a little more fuel capacity.)

[Nick-B]

Hey Jeff,

I have a '95 Santara and I've examined my fuel tank area and it "looks" like my tank was dropped in the past and I can only "assume" it was to change the pump. I really don't know for sure so one day I may have to do the same. GREAT PICTURES! But a bit of explanation would be appreciated.

What was the "bear" part of the job and was there anything you might have done different? Also, I see you purchased and entire replacement pump assembly (instead of just the electric pump itself). Did you buy a Ford part or an aftermarket replacement and what was the cost (if I can be so bold to ask)?

Thanks for posting and WELCOME TO THE FORUMS!

[KC1BUD]

??? Why had the pump been giving you any indications? How many miles on the Vehicle?
In all the years I have driven vehicles with the pump in the tank, not just motor homes either, never have I been stranded. I only had one vehicle that the pump had been replaced, and that vehicle had very high miles in excess of 120,000 miles. These things are designed to last over 100,000 miles.

As a side note did you all know that the gasoline also runs right through the pumps motor windings? They designed it so the gasoline cools the pump motor., kinda scary huh?

In case you wonder, I did some torture testing of tank pumps for a few weeks while I worked for GM.

[subford]

Hay Jeff,
A quick question. I do not see your exhaust tail pipes in the photos. Where do yours go out to the side?
A photo would be great.
Mine go over the rear axle and will hit the track bar I just put in so I need to rerun mine.
subford@gmail.com

Thanks
Bill K

[IRON WORM]

Thanks for the kind words and welcome to the site. The reason I changed the pump is because the 95-96 and some early 97 had a defective pump design and they are famous for failing on the road. I tow a race car and really don't want to break down. The new design doesn't use the fuel to cool it and is reported to be pretty bullet proof.
I replaced it with the new design Ford pump (part# PFS48, $364.79) and the Wiring Harness (part#WT56820, $24.89) required to adapt the old plug to the new pump. I bought these from RockAuto.com at probably half of what a Ford dealer would charge. You must solder the harness to the jumper harness (per Ford instructions) and use heat shrink over the connections. The new pump will extend about an inch above the tank when you drop it in there (surprise!). It's spring loaded so you push it down and bolt it in. I also replaced the fuel filler/vent hoses with new ones from Delta Rubber. They are Novaflex Marine Hose 2 inch (4 feet long for mine and $32.40) and the vent hose is common fuel line.
If I were to do it over again I'd run my tank lower on fuel (had to siphon out 30 gallons- good thing I had a lot of experience as a teenager) and drive the rear up on my leveling blocks- I pumped up my rear air bags and had just enough room to pull out the tank. And of course found some fool to help me. Other then that, I'm 60 years old and should have done it 12 years ago.
My exhaust system exits out between the step and the rear tire, I'll try and get a clear picture to post. If I missed something or can answer anything else, let me know. Jeff
www.theironworm.com

[LVJ58]

KC1BUD, Fuel pump failure in pre 1999 Fords was fairly common. It's my understanding the pumps for 1999 & later models had been redesigned to eliminate the problem that resulted in earlier model pump failure.

There was some speculation that earlier model pump failure resulted from the pump motor overheating when fuel in the tank dropped below a certain level as supposedly the fuel acted as a coolant for the pump motor.

Not sure what was changed in the newer pumps, but so far, I haven't read of any later model pump failures, but not to say there haven't been any.

Recently I had the deteriorating generator fuel line (hose) replaced in our coach which required dropping the tank. The service tech suggested that while the tank was down I might want to consider replacing the pump in our 2000 coach.

The original pump was working fine, but I decided to go ahead and have them replace the pump. I kept the original pump not sure why though..

[gene2]

I have an "06 F53 chassis that lost the fuel pump inconveniently at 20,000 miles. It was replaced under warranty at an independant Ford authorized shop. They were able to replace the pump by removing a crossmember behind the tank in less than 1 hour. I got to watch & is good to know as I usually DIY - former mechanic.

[blackf3504dr]

I have a question. When my coach sets for more then a couple weeks it is very hard to start, could this be a sign of the fuel pump failing ?

[subford]

Quote:

Originally Posted by blackf3504dr I have a question. When my coach sets for more then a couple weeks it is very hard to start, could this be a sign of the fuel pump failing ?

What MH do you have?
What year?
What class MH (A, B or C)?

[blackf3504dr]

Quote:

Originally Posted by subford What MH do you have? What year? What class MH (A, B or C)?

'92 HR on a F53 chassis.

[subford]

I would think not.
When the MH sets for mor then a few days just turn the key to run but do not crank the engine and back to off about three or four times. When you hear the pump quit for the last time in the on position crank the engine.

If you hear the pump run for more than one second each time you turn on the key and the engine will not start while the pump is running then you have sign of a failing PCM Computer.