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  #1  
Old 05-20-2012, 05:47 PM
El Bandito El Bandito is offline
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Default Replacing My Fuel Pump, 2004 4.0L

Since I bought my truck last October, the fuel pump has been dying a slow death. It's finally to the point where I need to replace it before I end up stranded and paying for a tow. It seems like the easiest way to access the pump is by removing the bed. I'm getting a buddy to come help me do the actual procedure on Tuesday, but I started today by removing my toolbox and bedliner. I'll post more pics on Tuesday when I remove the bed and replace the pump.

Before:



After removing toolbox and bedliner:



Damage from toolbox:



Cleaned out:

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2004 Black Ranger Edge Supercab
4.0L SOHC, 5 Spd Manual
Flowmaster 40 Series Single In Dual Out
31X10.50R15 Federal Couragia A/Ts
Bedlined: Mustang Dome, Explorer OHC w/ Buggman LED Panel , Radio Bezel
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Old 05-20-2012, 05:48 PM
djfllmn djfllmn is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

soak the bed bolts in PB blaster before you pull the bed off
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  #3  
Old 05-20-2012, 09:15 PM
Bwad Bwad is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

I don't mean to insult your intelligence, but have you replaced your fuel pump relay?

I replaced my fuse, then fuel filter, then fuel pump and my issue was still happening, so I decided to replace the relay and that fixed it. I wasted a lot of money, lol.
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Old 05-20-2012, 09:52 PM
El Bandito El Bandito is offline
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Default

Got some pb blaster, thanks for the tip. And no worries, Bwad, thanks for the heads up. I've already replaced all the cheap stuff, including the relay. I'm pretty sure it's the pump, but I guess we'll see..
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2004 Black Ranger Edge Supercab
4.0L SOHC, 5 Spd Manual
Flowmaster 40 Series Single In Dual Out
31X10.50R15 Federal Couragia A/Ts
Bedlined: Mustang Dome, Explorer OHC w/ Buggman LED Panel , Radio Bezel
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Old 05-21-2012, 07:54 AM
Bwad Bwad is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

Good luck in your endeavors. I was shocked that my 13ish year old fuel pump, at the time, was still working.
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  #6  
Old 05-28-2012, 02:44 PM
El Bandito El Bandito is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

I finished the project yesterday when some buddies came over for my birthday. It was an awesome day, and I'm glad to finally have a new fuel pump. And now the obligatory pictures:

Bed removed (removed 6 T-55 bolts, and disconnected the brake light harness under the rear bumper, then lifted the bed clear):



Old fuel pump (First I relieved the fuel pressure by disconnecting the inertia fuel shut-off switch and cranking the engine for 15 seconds. I disconnected the battery and cleaned all the debris from the top with compressed air. The fuel lines were easy to disconnect and required no special tool. Just press in on the colored part of the connector and pull. Removing the retaining ring was the toughest part. I had to have someone press down on the pump itself while I used a punch and hammer on the outside edge of the ring to slowly move it counterclockwise.):



New fuel pump!:



And now it's time for adult beverages:

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2004 Black Ranger Edge Supercab
4.0L SOHC, 5 Spd Manual
Flowmaster 40 Series Single In Dual Out
31X10.50R15 Federal Couragia A/Ts
Bedlined: Mustang Dome, Explorer OHC w/ Buggman LED Panel , Radio Bezel
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Old 05-28-2012, 06:38 PM
roper710 roper710 is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

El Bandito, Thought I would add a comment to this thread for anyone who is trying to do the the fuel pump change solo. I should stress this was a huge pain in the ass, but it was doable....and it was done in a few hours. First, I disconnected the fuel filler tube from the bed. Second I removed the front four torx bolts and loosened the back two almost all the way. Third, I began to tip the front of the bed up, brick by brick, until I had just enough room to work on the pump. Was tough. Here are a couple photos.
Attached Images
File Type: jpg IMG_0551.jpg (93.2 KB, 80 views)
File Type: jpg IMG_0548.jpg (94.5 KB, 85 views)
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Old 05-28-2012, 07:00 PM
doyouquaxu doyouquaxu is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

i've done roper's way before, but instead i tipped it to the passenger side and used a 2x4 stuffed in the wheel well opening to hold the bed. not the best or safest, but when you're stuck on the side of the road you gotta do what you gotta do.
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  #9  
Old 06-01-2012, 06:04 PM
El Bandito El Bandito is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

Very cool, guys. I admit, doesn't look very safe or easy, but like doyouquaxu said, whatever works in a pinch. Luckily I got some buddies to tow my truck to my place when the pump failed, but I was thinking about if I had to replace it alone, maybe moving the truck under a huge tree and using one of the branches to support a pulley system made of tie-down straps to lift the bed.. I think that might work, but I guess you'd have to be pretty sure about the strength of the branch. Either way, I'm glad I had some extra hands and wasn't stranded on the road.
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2004 Black Ranger Edge Supercab
4.0L SOHC, 5 Spd Manual
Flowmaster 40 Series Single In Dual Out
31X10.50R15 Federal Couragia A/Ts
Bedlined: Mustang Dome, Explorer OHC w/ Buggman LED Panel , Radio Bezel
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  #10  
Old 06-04-2012, 09:16 AM
El Bandito El Bandito is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

Update: over a week since fuel pump replacement, and no starting issues whatsoever. The truck seems to have more power and is getting much better mpg (17 in the city, up from about 14 before!). I think it's safe to say problem solved, but I'm not going to for fear of jinxing something.
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2004 Black Ranger Edge Supercab
4.0L SOHC, 5 Spd Manual
Flowmaster 40 Series Single In Dual Out
31X10.50R15 Federal Couragia A/Ts
Bedlined: Mustang Dome, Explorer OHC w/ Buggman LED Panel , Radio Bezel
Reply With Quote
  #11  
Old 08-26-2013, 09:11 PM
hart_tremor hart_tremor is offline
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Question Re: Replacing My Fuel Pump, 2004 4.0L

El Bandito where did you purchase your fuel pump
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  #12  
Old 06-07-2014, 03:00 PM
Jaf54 Jaf54 is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

This post was perfect!! Everything I needed to know. Thanks to all of you!!!
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  #13  
Old 06-07-2014, 10:53 PM
El Bandito El Bandito is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

(Months later... ) I got it from rockauto. Still going strong, no problems.
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2004 Black Ranger Edge Supercab
4.0L SOHC, 5 Spd Manual
Flowmaster 40 Series Single In Dual Out
31X10.50R15 Federal Couragia A/Ts
Bedlined: Mustang Dome, Explorer OHC w/ Buggman LED Panel , Radio Bezel
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  #14  
Old 10-05-2014, 02:16 AM
fastoed fastoed is offline
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Default Re: Replacing My Fuel Pump, 2004 4.0L

Quote:
Originally Posted by Bwad View Post
I don't mean to insult your intelligence, but have you replaced your fuel pump relay?

I replaced my fuse, then fuel filter, then fuel pump and my issue was still happening, so I decided to replace the relay and that fixed it. I wasted a lot of money, lol.
Where is the fuel pump relay?
Where can I get the parts breakdown with part numbers?
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