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Old 02-27-2021, 07:42 AM   #1
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Carry a spare fuel pump?

Looking through the archives it appears most with fuel pump problems have the 2003 and earlier pumps before the fuel return on the filter was added. I have a 2004 with the filter return and wonder about the logic of carrying a spare fuel pump? Traveling with a dog and two cats I do not want to be sitting in a motel waiting for a week for a new pump to arrive if mine decides to go south at some point. How common are failures on the 2004 and later pumps?
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Old 02-27-2021, 08:04 AM   #2
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We are at 140,000 km. with our rig and the fuel pressure still holds steady around 60 psi all the time.

I think the best thing to do for a long fuel pump life is never let your fuel level drop below 1/4. That way it stays cooled by the fuel. Running much lower the motor in the pump will be out of the fuel and run much warmer, shortening its life.
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Old 02-27-2021, 08:30 AM   #3
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We have a 2004 Georgie Boy Cruise Master with the 8.1engine and had a fuel pump failure at around 20K miles while on a trip. Changing the pump required dropping the fuel tank. We had it towed to a mechanic who replaced it. Not a job I would want to do on the road. Fresh water tank sits above the fuel tank so access from the top is not possible.
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Old 02-27-2021, 08:38 AM   #4
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Carry a spare fuel pump?

I have a 1995. I replaced mine out of caution(28 year old pump at the time) and since the fuel pump/ sending unit is under an accessible area of the floor. I cut a hatch in the floor to make it accessible without removing the tank. The hatch is under the carpet. I do keep a spare pump with me.
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Old 02-27-2021, 09:12 AM   #5
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My thought's. How many parts can you carry. If you are concern, change the part. After reading franks story. Im thinking about changing my pump with a fass. The old pump has no signs of problems, but I hate being on the side of the road.
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Old 02-27-2021, 11:55 AM   #6
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Quote:
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My thought's. How many parts can you carry. If you are concern, change the part. After reading franks story. Im thinking about changing my pump with a fass. The old pump has no signs of problems, but I hate being on the side of the road.
OP has a gasser with the 8.1, so different, but can be a b#ch to change if the tank is full!

I have read of someone on irv2 that installed an external high pressure fuel pump up under his rig with enough hoses to add it inline to the existing system. Just a matter of hooking it up, and flipping the prewired switch on if his pump failed. Maybe not a project for everyone, but it would save the day.
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Old 02-27-2021, 01:19 PM   #7
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My bad. Is it installed in the tank??? If so would you get the pump and fuel guage sending unit?

Yep with any fuel in the tank it's a pain.
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Old 02-27-2021, 02:15 PM   #8
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I installed an external aux fuel pump on our 2004 8.1 Workhorse. Source for fuel pickup is the tanks right side unused fuel filler and vent stub hoses. I used the vent stub for entry with a fabricated 3/8” nylon line.Tee fuel pump outlet into OEM fuel line just before fuel filter. I installed 1 way check valve on outlet side of pump, (did not trust pumps internal check valve). I used separate toggle switch with its own power source and fuse to power the pump. The pump is mounted on chassis frame cross member just in front of fuel tank. Works really well, hope I never have to use it!
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Old 02-27-2021, 04:44 PM   #9
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Kevin, who makes great videos about the W series Chassis did a great video on a fuel pump bypass that you can take along with you, if you have trouble with your in tank fuel pump. He even test drives the RV with the bypass.

https://youtu.be/AMwI6SF20KI
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Old 02-27-2021, 08:52 PM   #10
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I've considered the possibility of a back-up fuel pump, taking advantage of the unused fuel filler. Would certainly be nice to have that option if you're ever in a jam. Wouldn't be much fun on the side of the road, but seems like they often start acting up before they fail completely, and it would be an easy job to hook up the back up pump at a campground.
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Old 02-27-2021, 10:39 PM   #11
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I installed a fuel pressure gauge along with transmission temperature and manifold vacuum and volt gauges. Now I can see if the fuel pump is doing its thing at a glance. I just like to see that everything is perking along as it should.

If I see pressure dropping, first thing I will do is check the filter. Next would be the pressure regulator, then the pump.

I see no real need to just buy a spare pump. Lots of other things can go wrong, and I don't need to carry a complete parts department along.

So I guess what I'm trying to say is it's up to you what to carry along.
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Old 02-28-2021, 09:49 AM   #12
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Regular monitoring of a fuel pressure gauge does seem like a reasonable alternative to carrying a spare pump.
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Old 02-28-2021, 10:22 AM   #13
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Sounds like good advice. One can also listen to the pump. On my 454 TREK, I was advised that, if the pump whines, it may be getting ready to fail. Several years back, before a trip to the west coast, I heard the pump whining but thought it didn't sound too loud .

While in California, Coach.net towed us a few miles to a nice service location where I waited through the weekend to have a new pump in$talled.

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Regular monitoring of a fuel pressure gauge does seem like a reasonable alternative to carrying a spare pump.
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Old 03-01-2021, 12:05 AM   #14
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Electric Fuel pump bypass kit,W20 W22 W24 Workhorse Chassis with 8.1 Vortec Engine

Fuel pump used E16020 from O'Reilly Auto Parts Dorman steel fuel line number 800-155 New style Fuel filter and adapter Luber-finer # WHG481FK Adapter kit to convert Workhorse trucks with G2996, fuel filter to use G481 3/8 Gates hose # 27341 The 90 degree fitting at fuel filter along with connector I got at a local parts house that made hydraulic lines these fittings are called AN fittings.
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